For 1990-2009 cars

#### Tools Required

J 38185 Hose Clamp Pliers

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
2. Remove the battery tray.
3. Recover the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
4. Drain the cooling system. Refer to Cooling System Draining and Filling .
5. Use the J 38185 in order to reposition the upper radiator hose clamp.
6. Remove the upper radiator hose.
7. Remove the upper transaxle cooler line.
8. Use the J 38185 in order to reposition the surge tank hose clamp from the surge tank.
9. Remove the coolant surge tank hose.
10. Remove the condenser inlet fitting from the discharge hose.
11. Remove and discard the sealing washer.

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

12. Disconnect the cooling fan electrical connector.
13. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
14. Remove the lower closeout panel.
15. Use the J 38185 in order to reposition the lower radiator hose clamp from the radiator.
16. Remove the lower radiator hose from the radiator.
17. Remove the lower transaxle cooler line.
18. Remove the evaporator line from the condenser outlet.
19. Remove the lower radiator mounting panel.
20. Remove the radiator, fan and condenser as an assembly from the vehicle.
21. Remove the condenser from the radiator.
22. Remove the fan shroud from the radiator.

### Installation Procedure

1. Install the fan shroud to the radiator.

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.

2. Install the condenser to radiator bolts.

Tighten
Tighten the bolts to 5 N·m (44 lb in).

3. Install the radiator, fan, and condenser as an assembly to the vehicle.
4. Install the lower radiator mounting panel.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

5. Install the condenser outlet to the evaporator line bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

6. Use the J 38185 in order to reposition the lower radiator hose clamp to the radiator.
7. Install the lower radiator hose to the radiator.
8. Install the lower closeout panel.
9. Lower the vehicle.
10. Install the cooling fan electrical connection.
11. Install the lower transaxle oil cooler line.

Tighten
Tighten the fitting to 30 N·m (22 lb ft).

12. Remove the cap or tape from the discharge hose.
13. Install a new sealing washer to the discharge hose. Refer to Seal Washer Replacement on pages 1-45.
14. Install the condenser inlet fitting to the discharge hose.

Tighten
Tighten the fitting to 25 N·m (18 lb ft).

15. Install the coolant surge tank hose.
16. Install the upper transaxle oil cooler line fitting.

Tighten
Tighten the fitting to 30 N·m (22 lb ft).

17. Install the upper radiator hose.
18. Use the J 38185 in order to reposition the upper radiator hose clamp.
19. Refill the cooling system. Refer to Cooling System Draining and Filling .
20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
21. Leak test the fittings of the reinstalled components using the J 39400-A .
22. Install the battery tray.
23. Install the battery. Refer to Battery Replacement in Engine Electrical.