Radiator Replacement

Radiator Replacement

^ Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Remove the battery.
2. Drain the cooling system.





3. Remove the cooling fan assembly.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the lower air deflector.





6. Use J 38185 to remove the outlet hose clamp from the radiator.
7. Remove the outlet hose from the radiator.
8. Lower the vehicle.





9. Disconnect the transaxle oil cooler pipes from the radiator.
10. Pull the plastic cap back from the quick connect fitting and down along the transaxle oil cooler pipe.





11. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.





12. Remove the retaining ring from the quick connect fitting.
13. Discard the retaining ring.





14. Pull the transaxle oil cooler pipe straight out from the quick connect fitting.





15. Disconnect the coolant level sensor electrical connector.
16. In order to unlock the coolant level sensor, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion.
17. Remove the coolant level sensor.
18. Remove the radiator.

Installation Procedure





1. Install the radiator to the lower mounts.
2. Lubricate the O-ring seal of the coolant level sensor with coolant.
3. Place the snap clip leg in place.
4. Install the coolant level sensor.
5. Connect the coolant level sensor electrical connector to the coolant level sensor.





6. Install the transaxle oil cooler pipes.

Important: Install new retaining rings into the quick connect fittings.

7. Ensure the following procedures are performed when installing the new retaining ring onto the fitting.





8. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.





9. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.

Important: DO NOT Push the new retaining ring onto the fitting.





10. Installing the retaining ring on to the fitting this way will bend the retaining ring.





11. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.





12. Install the transaxle oil cooler pipes into the radiator quick connect fitting.





13. Insert the transaxle oil cooler pipe ends into the quick connect fitting until you hear or feel a click.





14. Do not use the plastic cap on the transaxle oil cooler pipe in order to install the transaxle oil cooler pipe into the fitting.
15. Pull back sharply on the transaxle oil cooler pipe in order to ensure that the transaxle oil cooler pipe is fastened into the quick connect fitting.





16. Position the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
17. Fully seat the plastic cap against the fitting.





18. Allow no gap between the cap and the fitting.





19. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating.

Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

20. Adjust the fluid level.
21. Raise the vehicle.
22. Install the outlet hose to the radiator.
23. Use J 38185 to install the outlet hose clamp to the radiator.
24. Install the lower air deflector.
25. Lower the vehicle.





26. Install the cooling fan assembly.
27. Fill the cooling system.
28. Install the battery.