How to replace a radiator in a 2002 pontiac van

For Pntiac Montana, Silhouette, Venture 2000-2005 check this removal & installation procedure...
WARNING Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

1. Recover the refrigerant from the A/C system.
   
2. Drain the cooling system.
   
3. Remove the cooling fans with the cooling fan shroud.
   NOTE Use the special tool J38185 to gently release tension on the hose clamp until the hose clamp lock feature engages allowing removal of the hose.
   
   
   

   Fig. Release tension from the hose clamp at the water pump housing using the special tool J38185 (click image for zoom).
   

4. Release tension from the hose clamp at the water pump housing using the special tool J38185
   
5. Disconnect the radiator outlet hose from the water pump housing.
   
6. Disconnect the lower TOC line from the radiator.
   
   
   

   Fig. Remove the nut which secures the A/C discharge hose to the condenser block
   

7. Remove the nut which secures the A/C discharge hose to the condenser block.
   
8. Disconnect the A/C discharge hose from the condenser block.
   
9. Remove and discard the sealing washer.
   NOTE Cap or tape off the open A/C hose immediately to prevent system contamination.
10. Cap or tape off the A/C discharge hose.
    
11. Remove the bolt which secures the evaporator inlet tube to the condenser block.
    
12. Disconnect the evaporator inlet tube from the condenser block.
    
13. Cap or tape off the evaporator inlet tube.
    
    
    

    Fig. Remove the radiator and condenser assembly
    

14. Remove the radiator and condenser assembly.
    
15. Release tension from the hose clamp at the radiator using the special tool J38185 .
    
16. Remove the lower radiator hose.
    
17. Remove the condenser tube clip bolt.
    
18. Remove the mounting bolts that secure the condenser to the radiator.
    
19. Remove the condenser from the radiator.

1. Install the condenser to the radiator.
   NOTE Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the mounting bolts that secure the condenser to the radiator and tighten the bolts to 53 inch lbs. (6 Nm).
   
3. Install the condenser tube clip bolt and tighten the bolt to 22 inch lbs. (2.5 Nm).
   
4. Install the lower radiator hose.
   NOTE Release the hose clamp retention lock by using a small flat bladed screwdriver.
5. Release the hose clamp retention lock at the radiator to secure the hose.
   
6. Install the radiator and condenser assembly.
   
7. Remove the cap or the tape from the evaporator inlet tube.
   
8. Install a new sealing washer to the evaporator inlet tube.
   
9. Install the evaporator inlet tube and the bolt to the condenser block and tighten bolt to 12 ft. lbs. (16 Nm).
   
10. Remove the cap or the tape from the A/C discharge hose.
    
11. Install a new sealing washer to the A/C discharge hose.
    
12. Install the A/C discharge hose and the nut to the condenser block and tighten the nut to 12 ft. lbs. (16 Nm).
    
13. Connect the lower TOC line to the radiator.
    
14. Connect the radiator outlet hose to the water pump housing.
    
15. Release the hose clamp retention lock at the water pump housing to secure the hose.
    
16. Install the cooling fans with the cooling fan shroud.
    
17. Fill the cooling system.
    
18. Evacuate and recharge the A/C system
    
19. Leak test the fittings of the component using the special tool J39400-A.
    
20. Inspect the transmission fluid level.

1. Disconnect the lower transmission oil cooler (TOC) line from the radiator.
   
2. Remove the cooling fans and shroud.
   
3. Remove the radiator inlet hose.
   
4. Remove the radiator outlet hose.
   
5. Remove the bolt that secures the radiator to the condenser.
   
6. Remove the condenser tube clip screw.
   
7. Tilt the radiator and condenser inward toward the engine and remove the radiator
   

1. Install the radiator.
   
2. Install the condenser tube clip screw.
   
3. Install the bolt that secures the radiator to the condenser.
   
4. Install the radiator hoses.
   
5. Install the cooling fan and shroud.
   
6. Connect the lower transmission oil cooler (TOC) line to the radiator.
   
7. Refill the cooling system.
   
8. Inspect the transmission fluid level.

How to replace a radiator in a 2002 Pontiac van
The vehicle's radiator is the component that removes heat from the engine through thermal heat exchange. It is usually located in the front of the vehicle under the hood. The engine creates heat from the internal combustion that continuously occurs inside the engine; this heat is transferred to the engine coolant, then circulated through the thermostat then to the radiator. Inside the radiator there are many small tubes with cooling fins attached that allows the coolant to be cooled and then returned to the engine in a continuous cycle. Radiators are mostly made of 2 plastic tanks and an aluminum core.
Step 1: Identify Radiator and Cooling System Components (under hood)
Radiator Identification
The thermostat housing is where the thermostat resides; it is connected to the radiator upper tank. The system is filled and checked at the radiator cap. The radiator is held in place by the radiator holder brackets and is usually near the top radiator tank. Some radiator configurations may vary in appearance but the concept is the same.
Step 2: Disconnect Negative Battery Terminal
Remove Negative Battery Terminal
Make sure the ignition key is in the off position, loosen the terminal pinch bolt and disconnect the battery terminal (gloves suggested). Anytime you perform repair work like this it is a good idea to disconnect the battery to avoid electrical short circuits. Always disconnect the negative battery cable to avoid a short to ground and NEVER let the wrench contact to positive side of the battery. Make sure the battery is clean at all times. If corrosion exists rinse battery with water (hose) and sprinkle with baking soda to naturalize the remaining acid.
Step 3: Drain Cooling System Locate Radiator Drain Plug
(Bottom View) Locate the radiator drain valve; turn it counter clockwise to loosen. On some cars there is a protective plastic splash guard that may need to be removed to access the radiator drain valve.
Step 4: Remove Lower Hose Connectihow to replace a radiator - tdisline_709.jpgdiator
Drain Radiator and Remove Lower Hose Connections
(Bottom View) After the coolant has drained completely, locate lower hose connections to remove clamps and hoses. If your vehicle has lower radiator mounts or cooling fan mounts, remove those bolts also. NOTE: (The cooling fan bolts are optional. Sometimes it is easier to disconnect the wires to the fans and remove the cooling fans with the radiator)
Remove Upper Radiator Hose Connections
Locate upper radiator hose to remove hose clamps and hose connection. Locate and remove upper cooling fan how to replace a radiator - tdisline_711.jpgs required.
Step 6: Remove Upper Radiator Mount
Locate and Remove Upper Radiator Mount Brakets
Locate upper radiator mounting brackets and remove the mounting bolts. If you have elected to remove the cooling fans with the radiator, locate the electrical connector and disconnect it as needed. If you are leaving the cooling fans behind when removing the radiator, remove the upper cooling fan mounting bolts. (Note in this photo an air impact gun is beinhow to replace a radiator - tdisline_712.jpgular wrench will work just fine).
Step 7: Remove and lift Radiator from Car
Lift Radiator From Car
After all previous steps have been completed; inspect the general area of the radiator making sure all other obstructions have how to replace a radiator - tdisline_713.jpgxt, lift radiator from vehicle removing the cooling fans if needed.
Step 8: Remove and Inspect Radiator
Inspect Old Radiator Once Removed
After removing the radiator from the vehicle, inspect thehow to replace a radiator - tdisline_714.jpgng hole location and other key mounting brackets. Now you are ready to install the new radiator.
Step 9: Replacing the New Radiator