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
12. Attach bracket #56405 on top of bracket #56403 and into upper cross frame on passenger’s side. You
will need to remove, and then reinstall a bolt previously installed in step #4. The “Z” shaped air ducting
is to be supported by this bracket.
ducting is routed differently.
(see detail 1 1)
Note:
Disregard bracket installation if your intake manifold’s air
13. Suggestions for securing A/C hoses to radiator bracket #56405:
a. If your intake manifold has the “Z” shaped air ducting, secure to underside of bracket #56405
with zip ties. (not included)
b. If your intake manifolds air ducting doesn’t take advantage of bracket #56405, rout the A/C
hoses atop the bracket and secure with zip ties. (not included)
14. Reattach flexible air duct to intake manifold. Be sure to also reattach integrated tube leading to passengers side valve cover.
15. Reattach “Z” shaped air ducting between air filter canister and flexible air duct.
Note:
If your vehicle
comes equipped with a strait forward or other air ducting configuration, reattach it instead.
16. Reattach negative (-) battery cable to battery.
17. Fill radiator/ cooling system with vehicle manufacturer recommended coolant. Remember to fill reservoir to “cold fill level” if needed.
Note: BE SURE that all moving parts of the engine and electrical fan assembly are clear of each other
before proceeding!
(Detail 7)
Upper cross
member
Metal support
bracket
Plastic bottom
fan bracket
Bracket
#56403 shown
mounted
(Detail 8)
Plastic/metal
bracket
assembly
Bracket
#56404 shown
mounted
Lower cross
member
(Detail 9)
(Detail 10)
Bracket
#56405 shown
mounted
(Detail 11)
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E. Fife, WA 98424, Telephone No. 253-922-2700, warrants to the original purchasing user, that all Flex-a-lite
products to be free of defects in material and workmanship for a period of 365 days (1 year) from date of purchase. Flex-a-lite products failing within
365 days (1 year) from date of purchase may be returned to the factory through the point of purchase, transportation charges prepaid. If, on inspection,
cause of failure is determined to be defective material or workmanship and not by misuse, accidental or improper installation, Flex-a-lite will replace the
product free of charge, transportation prepaid. Flex-a-lite will not be liable for incidental, progressive or consequential damages. Some states do
not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty
gives you specific legal rights and you may have other rights, which vary from state to state. The Flex-a-lite warranty in in compliance with the
Magnuson-Moss Warranty Act of 1975.
07-01-08 #99400 Page 3 of 3
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