Radiator: Service and Repair

REMOVAL





1. Disconnect negative battery cable.
2. Disconnect positive battery cable.

NOTICE: It is not necessary to disconnect fan control module wiring from module.

3. Remove fan control module by sliding up and off bracket. Lay module and wiring out of the way.
4. Remove battery insulating cover.
5. Remove battery hold down fan control module bracket.

CAUTION: DO NOT TIP BATTERY OVER 45 DEGREE ANGLE OR ACID COULD SPILL.

6. Remove battery.





7. Drain coolant. (Refer to "Draining Coolant".)
8. Remove power steering fluid reservoir to fan shroud bolts and position reservoir rearward in car.





9. Disconnect both cooling fan electrical connectors.
10. Remove electrical connectors from connector retainer by sliding connector as shown.
11. Remove pusher fan electrical harness from fan shroud retainer tabs.





12. Disconnect the auxiliary water pump electrical connector and remove harness from clip.





13. Remove upper transmission cooler line from radiator end tank and unsnap front end tank retainer.
14. Cap or tape off transmission oil cooler line to prevent oil loss or contamination.





15. Remove auxiliary water pump outlet hose to radiator end tank clamp and remove hose.





16. Remove upper radiator hose to radiator clamp and remove hose from radiator end tank.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

17. Raise vehicle.





18. Remove auxiliary water pump inlet hose to radiator end tank clamp and remove hose.
19. Lower vehicle.





20. Remove fan shroud to radiator bolts and remove.





21. Remove forward wiring harness from retaining clips (6).





22. Remove lower radiator hose to radiator clamp and remove hose.





23. Remove lower transmission cooler line from radiator end tank.
24. Cap or tape line and end tank to prevent oil spillage or contamination.





25. Remove radiator upper mount bracket to rail bolts and remove upper bracket and rubber mounts.





26. Remove radiator degas hose to radiator clamp and remove degas hose.
27. Using a piece of wire or plastic tie, support condenser from upper rail.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

28. Raise vehicle.

NOTICE: Do not open up the A/C system.





29. Remove condenser block to radiator end tank bolt.





30. Remove condenser to radiator bolts.
31. Pull condenser and pusher fan assembly down slightly to disengage tabs from radiator.
32. Lower vehicle.
33. Leaving condenser and pusher fan in vehicle, remove radiator from vehicle.





34. Remove upper and lower radiator to condenser gaskets.

INSTALLATION

1. Install upper radiator to condenser gasket on radiator.





2. Install radiator lower mounting pins into rubber mounts.





3. Install radiator degas hose to radiator end tank and position clamp at 1 o'clock.





4. Position upper radiator mounts over upper pins and install radiator bracket to rail bolts.
^ Torque: 6 Nm (53 inch lbs.)

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

5. Raise vehicle.





6. Position condenser tabs under radiator tabs and install condenser to radiator bolts.
^ Torque: 4 Nm (35 inch lbs.)





7. Install lower radiator to condenser gasket.





8. Install condenser block to radiator end tank bolt. ^ Torque: 4 Nm (35 inch lbs.)
9. Lower vehicle.
10. Remove condenser support wire or plastic tie.





11. Remove cap and install lower transmission cooler line to radiator end tank.
^ Torque: 4 Nm (35 inch lbs.)

IMPORTANT: White line on hose should be installed at 12 o'clock position.





12. Install lower radiator hose to radiator fitting.
13. Install clamp at 11 o'clock position.





14. Install forward wiring harness into forward rail clips.





15. Install fan and shroud assembly onto radiator lower tabs.

NOTICE: Verity that the pusher fan electrical harness is not between the fan shroud and the radiator.





16. Install fan shroud to radiator bolts.
^ Torque: 4 Nm (35 inch lbs.)

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

17. Raise vehicle.

IMPORTANT: Pusher fan wiring harness should be routed under auxiliary water pump outlet hose.





18. Install auxiliary water pump inlet hose to radiator end tank and install clamp so that tangs face outward.
19. Lower vehicle.





20. Route auxiliary water pump outlet hose under fan shroud tab then install to radiator end tank and install clamp at 12 o'clock position.





21. Install upper transaxle oil cooler line into radiator end tank retainer.
22. Remove cap and install upper transaxle oil cooler line to radiator end tank.
^ Torque: 25 Nm (18 ft. lbs.)





23. Connect circulation water pump electrical connector and install harness into clip.





24. Route pusher fan electrical harness around outside of radiator end tank to upper fan shroud.
25. Install fan electrical connectors into connector retainers as shown.
26. Connect both fan electrical connectors.
27. Install pusher fan harness under routing tabs on fan shroud.





28. Install upper radiator hose to radiator end tank and position clamp at 12 o'clock.





29. Install power steering fluid reservoir to fan shroud bolts.
^ Torque: 5 Nm (44 inch lbs.)





30. Verify battery tray is clean.
31. Install battery.
32. Install battery hold down/fan control module bracket.
^ Torque: 20 Nm (15 ft. lbs.)

NOTICE: Battery life is reduced if battery insulating cover is not used.

33. Install battery insulating cover.
34. Install fan control module by sliding down onto bracket.
35. Connect positive battery cable.
^ Torque: 17 Nm (13 ft. lbs.)
36. Connect negative battery cable.
^ Torque: 17 Nm (13 ft. lbs.)
37. Fill cooling system. (Refer to "Coolant Replacement".)
38. Use fresh water to rinse away any coolant that was spilled during service.