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Steve
Steve, Service Manager
Category: Chevy
Satisfied Customers: 5494
Experience:  25+ Years experience as a professional working automotive technician; ASE L1 master technician
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how do I remove radiator from 2004 malibu

This answer was rated:

I'm sure I can remove the radiator, but I don't know how to remove front facia(?) to get to the radiator.

Hello!

The fascia is not removed as part of the radiator replacement procedure on this model. This is a really nasty radiator to replace; I have printed the step by step procedure for remoiving the radiator for you below (please excuse teh numbering; the software we use to upload the steps changes the numbering sometimes, but they are all there in sequence).

THe labor guide says that it should take an experienced GM technician around 3 hours to complete a radiator replacement on this model. If you have never done the job before, it can sometimes take twice as long.

Here is the replacement procedure. IF this is helpful and answers your question, please click my accept button! Thanks!

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Removal Procedure

  1. Drain the coolant.
  2. Remove the left headlamp.
  3. Remove the right headlamp.
  4. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
  5. Remove the upper radiator support bracket bolts.
  6. Remove the upper radiator support brackets
    1. Reposition the surge tank outlet hose clamp at the radiator using the J 38185.
    2. Remove the surge tank outlet hose from the radiator.
    3. Reposition the radiator inlet hose clamp at the radiator using the J 38185.
    4. Remove the radiator inlet hose from the radiator
      1. Raise the vehicle. Refer to Vehicle Lifting.
      2. Remove the lower radiator air deflector retainers.
      3. Remove the lower radiator air deflector.
      4. Remove the right front fender liner.
      5. Remove the right radiator air deflector retainers.
      6. Remove the right radiator air deflector.
      7. Remove the left radiator air deflector retainers.
      8. Remove the left radiator air deflector
        1. Reposition the radiator outlet hose clamp at the radiator using the J 38185.
        2. Remove the radiator outlet hose from the radiator.
        1. Place a drain pan under the transmission oil cooler pipes.
        2. Remove the transmission oil cooler pipe attachment nut from the transmission.
        3. Remove the transmission oil cooler pipes from the transmission.
        4. Remove the lower radiator support bracket bolts.
        5. Remove the lower radiator support brackets.
        6. Remove the radiator lower mounts
        7. Remove and discard the condenser mounting bolts from the radiator.
        8. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
        9. Remove and discard the condenser mounting nuts from the radiator
        10. Remove the radiator air side seals
        11. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly
        12. Remove the transmission oil cooler pipes from the radiator.
        13. Pry upward on the fan shroud tabs at the radiator clips.
        14. Remove the cooling fan and shroud assembly
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