For 1990-2009 cars

#### Tools Required

AU-525 Quick Connect Release Tool

### Removal Procedure

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

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection .

Caution: Refer to Radiator Cap Removal Caution in the Preface section.

2. Ensure engine is below 50 C before removing the coolant pressure cap.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Remove the engine cover. Refer to Engine Cover Replacement for 3.6L engine or Engine Cover Replacement for 6.0L engine.
5. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement .
6. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement for 3.6L engine or Air Cleaner Inlet Duct Replacement for 6.0L engine.
7. Remove the mass air flow meter. Refer to Mass Airflow Sensor/Intake Air Temperature Sensor Replacementfor 3.6L engine or Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for 6.0L engine.
8. Detach the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle .
10. Remove the air deflector. Refer to Front Air Deflector Replacement .
11. Detach the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
12. Lower the vehicle.
13. Detach the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement .
14. Remove the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement .
15. Place a suitable container beneath the radiator and engine.

Caution: Refer to General Repair Instructions in the Preface section.

16. Disconnect the transmission cooler line (2) from the flexible hose (1) using the AU-525 .

• | Detach plastic cover from hose fitting and slide along pipe

• | Open the AU-525 then close and clip around the hose to be disconnected.

• | While holding the flexible hose (1) push the hose inwards with one hand, then pull back to separate from the steel hose piping (2).

• | Repeat procedure for the second fitting.

17. Remove the radiator support brackets (2) from top of radiator by rasing the securing lock (3) 10mm and then sliding the bracket off the radiator slide pin (1). Carry out same procedure for other bracket.
18. Disconnect the cooling fans electrical connector (2) from the main wiring loom connector (1).
19. Remove the two radiator and condenser retaining bolts (1).

Notice: Refer to General Repair Instructions in the Preface section.

20. Detach the condenser by lifting it out of the retaining brackets located on the radiator assembly.
21. Remove the radiator and fan assembly, by tilting it forward and lifting it out of the rubber grommets located in the cross member.

### Installation Procedure

1. Install the radiator into the rubber retaining grommets located in the cross member.
2. Install the condenser into the radiator

Notice: Refer to Fastener Notice in the Preface section.

3. Install the two radiator and condenser retaining bolts (1).

Tighten
Tighten the radiator and condenser bolts to 11 N·m (97 lb in).

4. Install the radiator retaining brackets (2), onto the radiator slide pin (1).
5. Secure the retaining brackets by pushing the securing lock (3) downwards until lock reaches bottom of radiator bracket.
6. Connect the cooling fans electrical connector (2) to the main wiring loom connector (1)

Caution: Refer to General Repair Instructions in the Preface section.

7. Connect the flexible hoses (1) to the transmission cooler lines (2), listen for an audible click to confirm fitting.
8. Push plastic cover forward along pipe and clip onto hose fitting.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle .
10. Install the outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement .
11. Lower vehicle.
12. Install the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement .
13. Install the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement .
14. Install the inlet hose. Refer to Radiator Inlet Hose Replacement .
15. Install the air deflector. Refer to Front Air Deflector Replacement .
16. Install the mass air flow meter. Refer to Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for 3.6L engine or Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for 6.0L engine.
17. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement for 3.6L engine or Air Cleaner Inlet Duct Replacement for 6.0L engine.
18. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement .
19. Install the engine cover. Refer to Engine Cover Replacement for 3.6L engine or Engine Cover Replacement for 6.0L engine.
20. Install the battery ground lead to the vehicle. Refer to Battery Negative Cable Disconnection and Connection .
21. Fill the cooling system. Refer to Cooling System Draining and Filling .
22. Inspect cooling system for leaks.