Radiator Replacement L81

1. Remove the battery. Refer to Battery Replacement in Engine Electrical.



2. Drain the coolant. Refer to Cooling System Draining and Filling .
3. Remove the bolts which secure the power steering fluid reservoir to the fan shroud.
4. Position the reservoir rearward in the car.



5. Disconnect both of the cooling fan electrical connectors.
6. Remove the electrical connectors from the connector retainer by sliding the connector as shown.
7. Remove the pusher fan electrical harness from the fan shroud retainer tabs.



8. Remove the upper transaxle cooler line from the radiator end tank and unsnap the front end tank retainer.
9. Cap or tape off the cooler line to prevent oil loss or contamination.



10. Remove the clamp which secures the upper radiator hose to the radiator.
11. Remove the upper radiator hose from the radiator.



12. Remove the fan shroud bolts.
13. Remove the fan shroud from the radiator.



14. Remove the forward wiring harness from the retaining clips.



15. Remove the lower radiator hose clamp.
16. Remove the hose from the radiator.



17. Remove the lower transaxle cooler line from the radiator.
18. Cap or tape the cooler line and the end tank to prevent oil spillage or contamination.



19. Remove the wiring harness clips from the upper radiator mounting bracket.
20. Remove the bolts from the radiator upper mount bracket.
21. Remove the bracket and the rubber mounts.



22. Remove the clamp from the radiator coolant air bleed hose.
23. Remove the hose from the radiator.
24. Using a piece of wire or a plastic tie, support the condenser from the upper rail.




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

25. Remove the bolt which secures the condenser block to the radiator end tank.



26. Remove the bolts which secure the condenser to the radiator.
27. Pull the condenser and the pusher fan assembly down slightly to disengage the tabs from the radiator.
28. Leaving the condenser and pusher fan in the vehicle, remove the radiator from the vehicle.



29. Remove the gaskets which separate the upper and the lower radiator from the condenser.

1. Install the gaskets between the upper and lower radiator and the condenser.



2. Install the radiator lower mounting pins into the rubber mounts.



3. Install the radiator coolant air bleed hose to the radiator.
4. Install the radiator coolant air bleed hose clamp at the 1 o'clock position.
5. Install the wiring clips to the upper radiator mounting bracket.



6. Position the upper radiator mounts over the upper pins.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the radiator bracket bolts

Tighten
Tighten the bolts to 6 N·m (53 lb in).

8. Install the wiring clips to the upper radiator mount bracket.



9. Position the condenser tabs under the radiator tabs.
10. Install the condenser to radiator bolts.

Tighten
Tighten the bolts to 4 N·m (35 lb in).




11. Install the lower radiator to the condenser gasket.



12. Install the bolt which secures the condenser block to the radiator end tank.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

13. Remove the condenser support wire or the plastic tie.



14. Remove the cap and install the lower transaxle cooler line to radiator.

Tighten
Tighten the cooler line to 4 N·m (35 lb in).





Important: The white line on the hose should be installed at the 12 o'clock position.

15. Install the lower radiator hose to the radiator.

Install the clamp at the 11 o'clock position.




16. Install the forward wiring harness into the forward rail clips.



17. Install the fan and shroud assembly onto the radiator lower tabs.




Important: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.

18. Install the bolts that secure the fan shroud to the radiator.

Tighten
Tighten the bolts to 4 N·m (35 lb in).




19. Install the upper transaxle oil cooler line into the radiator end tank retainer.
20. Remove the cap from the oil cooler line.
21. Install the oil cooler line to the radiator.

Tighten
Tighten the cooler line to 25 N·m (18 lb ft).




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



26. Install the upper radiator hose to the radiator.

Install the clamp to the 12 o'clock position.




27. Install the bolts which secure the power steering fluid reservoir to the fan shroud.

Tighten
Tighten the bolts to 5 N·m (44 lb in).




28. Install the battery. Refer to Battery Replacement in Engine Electrical.
29. Install the fan control module by sliding down onto the bracket.
30. Fill the cooling system. Refer to Cooling System Draining and Filling .