I have removed the spring clip on the bottom radiator hose (left hand side) on my 406 but cannot get the hose out. seems to be a push fit but its stuck. is there something I am missing. All othe hoses removed OK

remove items in this order and fit in reverse
1st-grill to help with access
2nd-cooling fan
3rd-fan shroud
4th-radiator hoses x3
5th-radiator
remember to remove the rubbers at the bottom of the old radiator to use on the new radiator

Carry out following work: Removing: - Undo and remove bolts -4- at top from radiator grille -1-. - Lever out spreader rivets -3- (Qty: 4) from below using a screwdriver. - Push thickness gauge -6- with the thickest feeler (1 mm) into space between radiator grille trim -2- and clip -5-. Note
This releases the latch -arrow-. - Using the front end hook -3370--7-, pull the radiator grille trim -2- out of the clip -5-"carefully" in -direction of arrow-. Fit on the right-hand side. - With help of a second mechanic, pull radiator grille trim -2- parallel out of the clips -5-. Caution
Radiator grille trim -2- is seated very tightly in the clips -5-.


- Remove bolts -2- on left and right. - Remove radiator grille -1- upwards.
IF U NEED FURTHER INFO LET ME KNOW..

Engine is cool!

drain coolant drain cock is at lower driver side .remove air cleaner.remove the electrical conaction.

remove right side diagonal brace remove upper radiator support and rotate reward remove the upper radiator hose remove upper radiator mount remove cooling fan shroud bolts "disconnect outlet hose from the water pump raise the vehicle disconnect outlet hose from the radiator

disconnect oil cooler hoses from top side of the radiator as follows

disengage the plastic cap from the quick connect fitting pull the plastic cap back along the pipe hold one leg of retaining clip

using a small bent screwdriver gently disengage the other end of the retaining clip from the quick content fitting rotate the retaining clip out of the quick connect fitting remove the retaining clip completely

remove the nut which secures the AC discharge hose remove the inlet tube remove radiator and condenser assembly

(Try to remove the radiator and keep the AC condenser In place)

1) Drain radiator by removing cap, and bottom radiator drain bung or bottom hose.
2) Remove top hose.
3) Disconnect the radiator fan's wiring and any temperature sensor wiring if fitted.
4) Remove radiator retaining clasps
5) Disconnect radiator bottom hose.
6) If fitted with an auto box, then remove automatic gearbox oil pipes (Underside)(you might wat to clasp these so they don't leak oil everywhere)
7) Remove radiator expansion bottle feed pipe from top of radiator.
8) Ease out the radiator. If the radiator fan is getting stuck or caught up, then drop the radiator back down and remove the fan first after disconnecting from the radiator body.
9) With new and old radiator placed side by side on a soft surface, change across any components from the old radiator, which didn't come with the new one. These may or may not include such things as: cap, fan retaining screws or clips, bottom radiator seating rubbers, rubber fan shrouding, temperature sensor, top and bottom rubber hoses.
10) Rebuild by reversing the above instructions. Apply silicone pipe sealant to top and bottom hose locations. Make sure you clean and/or replace any heavily corroded metal pipes which connect to the radiator. (Now is also a good opportunity to replace the thermostat to be on the safe side)

11) Fill system with a fresh 50/50 water/antifreeze mix, flush out and refill expansion bottle. Just before you refill the system, turn the interior heater setting up to maximum heat, but do not start the vehicle.
12) Top radiator up to max. Gently massage the top radiator hose to help eliminate air from the system.
13) Once filled, start the car. Pay attention to the temperature. Keep topping up the radiator as bubbles come around the system and the coolant level drops. At the point no more bubbles appear, close off the radiator with the cap. Allow the engine to reach normal operating temperature. If the weather is cold you may want to hold the engine at around 2,500 revolutions to help build heat faster. Keep it running until the radiator fan kicks in, then let it idle for a couple of minutes.
14) Stop the engine and let it cool.
15) Once cool, open the radiator cap and top up again if level is low.

16) Road-test the vehicle. After returning check again for any leaks.


Running the car for the first few days after radiator replacement, check the radiator level and expansion bottle level every day for the first two or three days. This level may drop slightly as any trapped air pockets are pushed out while running. Also, it is possible that any small leaks may begin after adding fresh anti-freeze to the system. If you begin loosing fluid over these first few days, then re-inspect your work and run a cooling system pressure test.

Pug 406 radiator change -
drain the coolant
remove top and bottom hose clips and the thin hose remove sensor multi plug
remove hoses
flick up clips at top of rad
lift it out!! that's it !!
replace in reverse order making sure the bottom locating pin rubber grommets are in place.
Hope this helps youKind regards

If you are changing upper and lower radiator hoses too...you can skip the drain plug...and drain by disconnecting the lower radiator hose...Your hoses are a wera item too:)

1994 Saturn SLx Radiator replacement

Tools Needed:
3/8" ratchet
10mm socket
10mm deep well socket
6" extension


1. Jack up car and support using jack stands.

2. Start by removing the air tube over radiator by pulling off the 2 small plastic clips attached over the radiator. There is also a sensor connected on the bottom right side near the airbox, so don't just yank it off.

3. Remove the airbox using the 10mm socket with 6" extension - there are three 10mm bolts holding it down - two behind the airbox and one in front.

4. Undo the clips holding the wires for the fan and o2 sensor, then disconnect the connector for the fan.

5. Undo the single 10mm bolt holding the fan to the radiator on the drivers side. Lift up on the left hand side and work the fan housing out at an angle. Careful of the A/C lines - don't force it. The wire clips may bind on the A/C lines, I removed the top wire clip and it made it easier to get out.

6. Remove radiator cap and drain radiator. Simply turn the drain plug on the passenger side and let it drain - it took about 10 minutes to fully drain for me.

7. Undo the two 10mm bolts holding the radiator brackets using the deep well socket.

8. Drain block - single 10mm bolt under the lower radiator hose / thermostat housing.

9. Remove upper radiator hose.
10. Remove Lower radiator hose.
10a. If you have an automatic transmission disconnect the cooler lines at this point, using a flare nut wrench. If you cannot get them off, you can remove them at the transmission side, and purchase new ones from the dealer. Plan on these not coming off, if the car is more than 6 or 7 years old.
11. Remove the two 10mm bolts (one on driver side and one on passenger side) holding the AC condenser to the front of the radiator. These can be a pain to get off - lift the radiator and condenser as a unit out of the rubber mounts to give you enough room to get a ratchet in there from the front, under the bumper.

12. Lift up on the right side of the radiator to let it drain the rest of the way (there will still be a little coolant left after you drained it.)

13. Install new radiator. You may need to remove the metal clips for the bolts off the old radiator and install them on the new one. Reconnect the two 10mm bolts holding the condenser to the radiator on the same way you took them off - this is a real pain. Reconnect the two 10mm bolts for the upper brackets of the radiator using the 10mm deep well socket.

14. Re-install the upper radiator mounts.

15. Install lower radiator hose. Now is a good time to replace the hoses. Use hose grease to make it much easier to get them on. It is also a good time to replace the clamps.

16. Install fan - be sure to re-clip the o2 sensor wire and fan wires, otherwise they may get caught in the fan. Re-connect the fan connector.

17. Install new upper radiator hose. Before you install this it is a good time to replace the ECTS if you still have the original plastic tipped one, it's easier to get to.

17a. Auto Transmission - reconnect the cooler lines.

18. Reinstall airbox, air ducts, re-connect the air temperature sensor.

19. Refill radiator. You will need to check the level periodically over the next few days and add as necessary.

Radiator Removal & Installation To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect negative cable.
3. Drain cooling system.
4. Remove or disconnect the following:
   • Radiator upper crossmember
   • Upper and lower coolant hoses from the radiator
   • Transmission hoses from cooler
   • Engine oil cooler lines (if equipped)
   • Radiator fan electrical connector and fan assembly
   • Condenser mounting screws located at the front of the radiator
   • Transmission cooler line bracket from left side of radiator
5. Lift condenser upward enough to disengage upper mounting clips. Allow condenser to rest on lower radiator crossmember.
6. Lifted radiator from engine compartment.

To Install:

1. Seat the radiator assembly lower rubber isolators into the mounting holes in radiator lower support.
2. Attach air conditioning condenser to radiator
   • Torque to 45 inch lbs. (5 Nm)
3. Install or connect the following:
   • Radiator lower hose
   • Transmission cooler line bracket and transmission hoses
     1. Torque to 28 inch lbs. (3 Nm)
   • Radiator fan and electrical connector
   • Engine oil cooler lines (if equipped)
     1. Torque to 160 inch lbs. (18 Nm)
   • Radiator upper hose
   • Radiator upper support crossmember
   • Negative cable
4. Fill cooling system with coolant.

First remove the fan shroud - undo the two clips on the left and right by pulling up. It should be possible to now ease the shroud upwards passed the fan. Drain the coolant (there is red valve on the right hand side lower corner of the radiator for this purpose) Remove the top and lower hoses. Un-clip the side panels that fill the gaps either side of the radiator aperture. Remove the two top clips, by pulling them upwards, that secure the radiator to the car body cross member at the front. The radiator should just lift up and out. Beautifully simple German design.

give these websites a try www.alldatadiy.com and www.autozone.com if all fails stop by your local library and get your hands on a Haynes auto repair manual for your car.