Flex-a-Lite 56400 User Manual

Camaro Radiator #56400

Fits 1982-1992

INSTALLATION INSTRUCTIONS

REMOVAL OF EXISTING FAN AND SHROUD ASSEMBLY:

1. Make sure the engine is cool!

2. Disconnect negative (-) battery cable from battery.

3. Remove “Z” shaped air ducting between air filter canister and flexible air duct.
comes equipped with a strait forward or other air ducting configuration, remove it.

4. Remove remaining flexible air duct attached to intake manifold. Remove intergraded tube as well
leading to passenger side valve cover.

5. Remove air ducting support bracket from top radiator bracket, and remove or detach Air Conditioning
(A/C) lines (if equipped) from shroud.

6. Pull A/C lines away from top of radiator and hold in place over motor; this gets the hoses out of the way
for better access.

7. Remove electrical or clutch fan at this time

8. Release wire loom from mounts on lower metal support bracket (supporting bottom radiator hose). Pull
bottom radiator hose out of bracket.

9. Remove the bolts holding together the following items:

a. Power steering cooling lines.
b. Lower frame cross member.
c. Plastic bottom fan bracket.

fan bracket and bolts during new radiator installation.

10. Remove radiator cap and drain radiator; drain valve is on passenger side at bottom.

11. Disconnect the following:

a. Overflow hose leading to coolant reservoir.
b. Bottom radiator hose from radiator and let remaining coolant drain.
c. Top radiator hose from radiator.

12. Remove the bolts (4) securing top radiator bracket to top cross member and top of radiator.
the bolts to be reused later.

13. Pull the original radiator up & out from the engine compartment then set it aside.

14. Clean out any debris (leafs, bugs, dirt, coolant) from bottom cross member where original radiator
previously rested.

Tip:

Try using long zip ties to secure loose objects in place as needed.

(see detail 2)

(see detail 1)

(see detail 3 on page 2)

Note:

You will be reusing the metal support bracket, plastic bottom

(see detail 8 on page 3)

Note:

If your vehicle

(see detail 1)

Note:

(see detail 4 page 2)

Save

(Detail 1)

Flexible air duct

Top radiator bracket

(Detail 2)

07-01-08 #99400 Page 1 of 3

INSTALLATION OF NEW RADIATOR:

1. Start by removing the bottom rubber radiator mounts. Trim the rubber mounts flat across the top to
allow for the flat bottomed FAL radiator to sit flush on top of them.
mounts, located back to original positions.

2. Gently lower the fan mounted radiator into engine compartment and place the radiator on top of the
rubber mounts.
driver’s side. You may need to slightly modify location of lines to fit space with radiator side tank. Shift
radiator side to side until centered.

3. Attach bracket #56403 to radiator top, but do not tighten. Align bracket slots to brass inserts using 2ea.
5/8” long ¼-20 bolts and flat washers provided.

4. Attach lower half of bracket #56403 to upper cross member reusing the bolts (2) saved from step #12 of
the removal instructions but do not tighten yet.

5. Verify radiator base is nested inside lower cross member on top of rubber mounts then tighten all bolts
thru bracket #56403. The radiator should be secured at this point.

6. From below the vehicle, thru the lower frame cross member, reuse saved bolts (2) from step #9 of the
removal instructions and reinstall:

a. Power steering cooling lines.
b. Plastic bottom fan bracket and metal support bracket assembly.

7. Reattach bottom radiator hose and replace hose into metal support bracket.

8. Reattach wire loom to mounts on metal support bracket.

9. Remove barbed hose fitting with 1/8” NPT thread from hardware kit and screw into radiator filler neck.
Attach overflow hose leading to coolant reservoir.

10. Reattach top radiator hose.

11. Attach bracket #56404, on top of bracket #56403, on driver’s side. You will need to remove, and then
reinstall, a bolt previously installed in step #3. The top radiator hose is to be supported by this bracket.

Note:

tage of the bracket.

Disregard bracket installation if your upper radiator hose is routed in a way that can’t take advan-

Note:

Installing the radiator at this point will be complicated by power steering lines on

(see detail 6)

(see detail 7 page 3)

(see detail 10&1 1 page 3)

(see detail 5)

Reinstall rubber

(see detail 8&9 page 3)

(Detail 3)

Wire loom

Wire loom
mounts

Showing lower
cross member w/
radiator removed

Clean debris
from this space

(Detail 4)

Trim line

(Detail 5)

(Detail 6)

07-01-08 #99400 Page 2 of 3