Radiator Replacement

Radiator Replacement

^ Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure





1. Drain the cooling system.
2. Remove the battery.
3. Remove the engine cooling fans.
4. Remove the upper radiator brackets and bolts.





5. Use the J 38185 in order to reposition the hose clamp from the radiator inlet hose.
6. Remove the radiator inlet hose from the radiator.
7. Raise and support the vehicle. Refer to Vehicle Lifting.
8. Remove the lower air deflector.
9. Use the J 38185 in order to reposition the hose clamp from the radiator outlet hose.
10. Remove the radiator outlet hose from the radiator.





11. Disconnect the transaxle oil cooler pipes from the radiator.
12. Pull the plastic cap back from the quick connect fitting and down along the transaxle oil cooler pipe about two inches.





13. 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.





14. Remove the retaining ring from the quick connect fitting.
15. Discard the retaining ring.





16. Pull the transaxle oil cooler pipe straight out from the quick connect fitting.
17. Lower the vehicle.
18. Disconnect the electrical connector from the coolant level module.
19. In order to unlock the coolant level module, lift one leg of the snap clip from its locked position and pull outward with a slight twisting motion.
20. Remove the coolant level module.
21. Remove the radiator.

Installation Procedure





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





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 radiator outlet hose to the radiator.
23. Use the J 38185 in order to reposition the hose clamp to the radiator outlet hose.
24. Install the lower air deflector.
25. Lower the vehicle.
26. Install the radiator inlet hose to the radiator.
27. Use the J 38185 in order to reposition the hose clamp to the radiator inlet hose.





Notice: Refer to Fastener Notice in Service Precautions.

28. Install the upper radiator brackets and the upper radiator bracket bolts.
^ Tighten the bolts to 24 Nm (18 ft. lbs.).
29. Install the engine cooling fans.
30. Install the battery.
31. Fill the cooling system.