Radiator: Service and Repair

RADIATOR-2.5L ENGINE
REMOVAL

WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.

1. Disconnect battery negative cable.
2. Drain cooling system. Refer to Draining and Filling, under Cooling System Service and Repain.

Hose Clamp Tool-Typical:

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

Clamp Number/Letter Location:

CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.

3. Remove hose clamps and hoses from radiator. Remove coolant reserve/overflow tank hose from radiator filler neck.
4. Disconnect electric cooling fan motor connector. Remove fan and shroud upper attaching clips. Lift fan and shroud assembly up and out. Do not allow fan shroud to contact radiator cooling fins. Radiator fin damage could result.

Radiator And Fan Shroud Removal/Installation-Typical:

5. Remove radiator upper mounting screws. Lift radiator up and out of engine compartment. Do not allow cooling fins of radiator to contact any other vehicle component. Radiator fin damage could result.


INSTALLATION
The radiator has two alignment pins on bottom of lower tank. These fit into alignment holes in radiator lower support.
1. Lower the radiator into engine compartment. Position alignment pins into alignment holes in radiator lower support.
2. Install and tighten radiator mounting bolts to 23 Nm (200 inch lbs.)
3. Lower radiator fan and shroud assembly into retaining pockets on radiator lower tank.
4. Attach retaining clips at top of shroud.
5. Connect fan motor electrical connector to harness connector.
6. Install radiator hoses and coolant reserve/overflow tank to radiator hose.
7. Connect battery negative cable.
8. Fill cooling system. Refer to Draining and Filling found under Cooling System, Service and Repair.
9. Start and warm the engine. Check for leaks.