For 1990-2009 cars

## Radiator Replacement Gasoline

### Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to Cooling System Draining and Filling.
3. Remove the main and the auxiliary cooling fans. Refer to Engine Coolant Fan Replacement.
4. Remove the upper radiator retaining bolt.
5. Remove the upper radiator retaining bracket.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radiator.
8. Remove the hose clamp from the surge tank hose at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the lower radiator hose clamp.
11. Disconnect the lower radiator hose from the radiator.
12. Disconnect the transaxle cooler pipes from the lower radiator tank, if equipped.
13. Remove the bolt and the transaxle pipe support clamp from the radiator.

Note: The radiator still contains a substantial amount of coolant. Drain the remainder of the coolant from the radiator into a drain pan.

14. Remove the radiator from the vehicle.

### Installation Procedure

1. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.
2. Connect the transaxle cooler pipe to the lower radiator tank, if equipped.
3. Install the transaxle pipe and support clamp to the radiator with a bolt.
4. Connect the surge tank hose to the radiator.
5. Secure the surge tank hose with a hose clamp.
6. Connect the upper radiator hose and the lower radiator hose to the radiator.
7. Secure each hose with a hose clamp.
8. Position the radiator retainers in place.

Caution: Refer to Fastener Caution in the Preface section.

9. Install the upper radiator retainer bracket.
10. Install the upper radiator retaining bolt and tighten to 14 N·m (10 lb ft).
11. Install the main and the auxiliary cooling fans. Refer to Engine Coolant Fan Replacement.
12. Fill the engine cooling system. Refer to Cooling System Draining and Filling.
13. Connect the negative battery cable.

## Radiator Replacement Diesel

Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Remove the beauty cover. Refer to Engine Cover Replacement.
2. Remove the battery and tray. Refer to Battery Tray Replacement.
3. Drain the engine coolant. Refer to Cooling System Draining and Filling.
4. Remove the charge air cooler inlet/outlet hoses. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
5. Remove the glow plug fuse box.
6. Remove the main cooling fan. Refer to Engine Coolant Fan Replacement.
7. Remove the radiator upper bracket.
8. Remove the transaxle oil cooler hoses from the radiator, if equipped.
9. Remove the A/C condenser pipes from the condenser.
10. Remove the radiator assembly upward.
11. Remove the auxiliary cooling fan from the A/C condenser.
12. Remove the A/C condenser from the charge air cooler.
13. Remove the charge air cooler from the radiator.

### Cleaning Procedure

| Note: The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. Some conditions may require the use of warm water and a mild detergent.

• | Clean the radiator cooling fins.

• | Straighten any damaged cooling fins

### Installation Procedure

Note: Use care when handling the radiator to prevent fin damage and ensure proper cooling.

1. Install the charge air cooler to the radiator.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the A/C condenser.

• | Tighten the charge air cooler retaining bolts to 8.5 N·m (75.2 lb in).

• | Tighten the A/C condenser retaining bolts to 9 N·m (80 lb in).

3. Install the auxiliary cooling fan and tighten the retaining bolts to 4 N·m (35 lb in).
4. Install the radiator assembly.
5. Install the radiator upper bracket and tighten the bracket bolts to 14 N·m (10.3 lb ft).