Radiator Support Replacement Lower

1. Remove the air cleaner and the air duct.
2. Discharge the A/C system. Refer to Section 1B1.
3. Remove the radiator. Refer to Radiator Replacement .
4. Disconnect the A/C lines at the condenser. Remove the A/C condenser. Refer to Section 1B.



5. Remove the radiator lower support.

1. Install the lower radiator support.
2. Install the A/C condenser and lines. Refer to Section 1B.

Tighten

•	Tighten the evaporator hose to condenser fitting to 16 N·m (12 lb ft).

•	Tighten the compressor hose to condenser fitting to 40  N·m (30 lb ft).

Notice: 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.

3. Install the radiator. Refer to Radiator Replacement .
4. Recharge the A/C system. Refer to Section 1B1.



5. Install the air cleaner and the air duct.

Radiator Support Replacement Upper

Tools Required

J 38185 Spring Hose Clamp Pliers

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Disconnect the negative battery cable. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   in General Information.



2. Remove the air cleaner and the air duct.
3. Drain the coolant. Refer to Cooling System Draining and Filling .



4. Remove the air bleed hose and the clamp at the radiator.



5. Remove the transmission cooler lines (Automatic transmission).



6. Remove the screws retaining the fan relays. Remove the relays.



7. Remove the electrical connectors at the Secondary Air Injection (AIR) pump and the horn.
8. Remove the Secondary Air Injection (AIR) pump.
9. Remove the bolts retaining the shroud to the upper radiator support.
10. Remove the bolts retaining the radiator upper support to the lower support.



11. Remove the radiator upper support.

1. Install the radiator upper support.
2. Install the screws retaining the upper support to the lower support.

Tighten
Tighten the screws retaining the lower radiator support to the upper radiator support to 9 N·m (80 lb in).

Notice: 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.

3. Tighten the nuts and bolts retaining the upper support to the side member.

Tighten
Tighten the bolt retaining the radiator upper support to the side member to 25 N·m (18 lb ft).




4. Install the Secondary Air Injection (AIR) pump and the retaining bolts.

Tighten
Tighten the Secondary Air Injection (AIR) pump retaining bolts to 10 N·m (89 lb in).

5. Install the electrical connectors at the Secondary Air Injection (AIR) pump and the horn.



6. Install the fan relays and retaining screws.

Tighten
Tighten the relay retaining screws to 9 N·m (80 lb in).




7. Install the transmission cooler lines to the radiator (Automatic transmission).



8. Install the air bleed hose and the clamp to the radiator.



9. Install the air cleaner and the air duct.
10. Refill the cooling system. Refer to Cooling System Draining and Filling .
11. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11  lb ft).