Radiator: Service and Repair

Radiator Replacement

^ Tools Required
- J 38185 Hose Clamp Pliers
- J 39400-A Halogen Leak Detector

Removal Procedure





1. Remove the battery.
2. Remove the battery tray.
3. Recover the A/C system.
4. Drain the cooling system.
5. Use the J 38185 in order to reposition the radiator inlet hose clamp (1).
6. Remove the radiator inlet hose (2) from the radiator.
7. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (4) from the surge tank.
8. Remove the surge tank outlet/radiator outlet hose (6) from the surge tank.
9. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (7) from the radiator.
10. Remove the surge tank outlet/radiator outlet hose (6) from the radiator.





11. Remove the upper transaxle cooler line.





12. Remove the refrigerant pressure sensor electrical connector.





13. Remove the condenser inlet fitting from the discharge hose.

Important: Cap or tape off the open A/C hose to prevent system contamination.

14. Remove and discard the sealing washer.





15. Disconnect the cooling fan electrical connector.





16. Raise the vehicle.
17. Remove the lower closeout panel.
18. Remove the lower transaxle cooler line fitting.





19. Remove the bolt from the evaporator hose to the condenser.
20. Remove the evaporator hose from the condenser.
21. Remove and discard the seal washer.





22. Remove the lower radiator support mounting panel.





23. Remove the radiator, fan and condenser as an assembly from the vehicle.





24. Remove the fan shroud from the radiator.
25. Remove the condenser from the radiator.

Installation Procedure





1. Install the fan shroud to the radiator.





2. Install the condenser to the radiator.
3. Install the condenser to radiator bolts.
^ Tighten the bolts to 5 Nm (44 inch lbs.).

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the radiator, fan, and condenser as an assembly to the vehicle.





5. Install the lower radiator support mounting panel.
^ Tighten the bolts to 10 Nm (89 inch lbs.).





6. Remove the cap or tape from the evaporator hose.
7. Install a new seal washer on the condenser end of the evaporator hose assembly.
8. Install the evaporator hose to the condenser outlet.
9. Install the condenser outlet to the evaporator line bolt.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





10. Install the lower transaxle cooler line fitting.
^ Tighten the fitting to 30 Nm (22 ft. lbs.).





11. Install the cooling fan electrical connectors.





12. Install the lower closeout panel.
13. Lower the vehicle.
14. Install the surge tank outlet/radiator outlet hose (6) to the radiator.
15. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (7) to the radiator.
16. Install the surge tank outlet/radiator outlet hose (6) to the surge tank.
17. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (4) to the surge tank.
18. Install the radiator inlet hose (2) to the radiator.
19. Use the J 38185 in order to reposition the radiator inlet hose clamp (1) to the radiator.





20. Remove the cap or tape from the discharge hose.
21. Install a new sealing washer to the discharge hose.
22. Install the condenser inlet fitting to the discharge hose.
^ Tighten the fitting to 25 Nm (18 ft. lbs.).





23. Install the refrigerant pressure sensor electrical connector.





24. Install the upper transaxle oil cooler line fitting.
^ Tighten the fitting to 30 Nm (22 ft. lbs.).
25. Refill the cooling system.
26. Recharge the A/C system.
27. Leak test the fittings of the reinstalled components using the J 39400-A.
28. Install the battery tray.
29. Install the battery.