For 1990-2009 cars

## Radiator Replacement L61

### Removal Procedure

1. Remove the battery.
2. Drain the coolant. Refer to Draining Coolant .
3. Disconnect both cooling fan electrical connectors.
4. Remove the electrical connectors from the connector retainer by sliding the connector.
5. Remove the pusher fan electrical harness from the fan shroud retainer tabs.
6. Remove the wiring harness from the clamp on the fan shroud.
7. Perform the following for automatic transaxles only:

7.1. | Remove the upper transaxle cooler line from the radiator end tank.

7.2. | Cap or tape off the transaxle oil cooler line to prevent oil loss or contamination.

7.3. | Remove the upper transaxle oil cooler line from the radiator end tank clip.

8. Remove the upper radiator hose to the radiator clamp and remove the hose from the radiator end tank.
9. Remove the fan shroud to the radiator bolts and the shroud assembly.
10. Remove the forward wiring harness from the retaining clips.
11. Remove the lower radiator hose to the radiator clamp and remove the hose.
12. Perform the following steps for automatic transaxles only:

12.1. | Remove the lower transmission cooler line from the radiator end tank.

12.2. | Cap or tape the line and the end tank to prevent oil spillage or contamination.

13. Remove the radiator upper mount bracket to the rail bolts and remove the upper bracket and rubber mounts.
14. Using a piece of wire or a plastic tie, support the condenser from the upper rail.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

15. Raise the vehicle.

Important: Do not open up the A/C system.

16. Remove the condenser block to the radiator end tank bolt.
17. Remove the liquid line to the condenser bolt (right side).
18. Remove the condenser to the radiator bolts.
19. Pull the condenser and the pusher fan assembly down slightly to disengage the tabs from the radiator.
20. Lower the vehicle.
21. Leaving the condenser and the pusher fan in the vehicle, remove the radiator from the vehicle.
22. Remove the upper radiator to the condenser gaskets.

### Installation Procedure

1. Install the upper radiator to the condenser gasket on the radiator.
2. Install the radiator lower mounting pins into the rubber mounts.
3. Position the upper radiator mounts over the upper pins and install the radiator bracket to rail bolts.

Tighten
Tighten the radiator bracket-to-rail bolts to 6 N·m (53 lb in).

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

4. Raise the vehicle.
5. Position the condenser tabs under the radiator tabs and install the condenser to radiator bolts.

Tighten
Tighten the condenser to radiator bolts to 4 N·m (35 lb in),

6. Install the lower radiator to the condenser gasket if removed.
7. Install the liquid line clamp to the condenser bolt.

Tighten
Tighten the liquid line clamp-to-condenser bolt to 4 N·m (35 lb in).

8. Install the condenser block to radiator end tank bolt.

Tighten
Tighten the condenser block-to-radiator end tank bolt to 4 N·m (35 lb in).

9. Lower the vehicle.

Important: Perform the following step on automatic transaxle vehicles only.

10. Remove the cap and install the lower transmission cooler line to radiator end tank.

Tighten
Tighten the lower transmission cooler line to radiator end tank to 25 N·m (18 lb ft).

Important: The white line on the hose should be installed at the 12 o'clock position.

11. Install the lower radiator hose to the radiator fitting.
12. Install the clamp at the 11 o'clock position.
13. Remove the condenser support wire or plastic tie.
14. Install the fan and the shroud assembly onto the radiator lower tabs.

Important: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.

15. Install the fan shroud to the radiator bolts.

Tighten
Tighten the puller fan shroud to radiator bolts to 4 N·m (35 lb in).

16. Perform the following steps on automatic transaxle vehicles only:

16.1. | Remove the cap and install the upper transmission oil cooler line to radiator end tank.

16.2. | Snap the upper transmission oil cooler line into the end tank retainer.

Tighten
Tighten the upper transmission cooler line to radiator end tank to 25 N·m (18 lb ft).

17. Install the forward wiring harness into the retaining clamps.
18. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
19. Install the fan electrical connectors into the connector retainers as shown.
20. Connect both of the fan electrical connectors.
21. Install the wiring harness into the shroud retaining clamp.
22. Install the pusher fan harness into the routing tabs on the fan shroud.
23. Install the upper radiator hose to radiator end tank and position the clamp at 12 o'clock.
24. Install the battery.

## Radiator Replacement L81

### Removal Installation

1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery insulating cover.
4. Remove the battery hold down bracket.
5. Remove the battery heat shield.

• | Christmas tree fastener (1)

• | Push pin fastener (1)

Caution: Do not tip the battery over a 45 degree angle or acid could spill causing serious personal injury.

6. Remove the battery.
7. Drain the coolant. Refer to Draining Coolant .
8. Remove the power steering fluid reservoir to fan shroud bolts and position the reservoir rearward in the car.
9. Disconnect both of the cooling fan electrical connectors.
10. Remove the electrical connectors from the connector retainer by sliding the connector as shown.
11. Remove the pusher fan electrical harness from the fan shroud retainer tabs.
12. Remove the upper transaxle cooler line from the radiator end tank and unsnap the front end tank retainer.
13. Cap or tape off the transaxle oil cooler line to prevent oil loss or contamination.
14. Remove the upper radiator hose to the radiator clamp and remove the hose from the radiator end tank.
15. Remove the fan shroud to the radiator bolts and remove the shroud.
16. Remove the forward wiring harness from the retaining clips.
17. Remove the lower radiator hose to radiator clamp and remove the hose.
18. Remove the lower transaxle cooler line from the radiator end tank.
19. Cap or tape the line and the end tank to prevent oil spillage or contamination.
20. Remove the wiring harness clips from the upper radiator mounting bracket.
21. Remove the radiator upper mount bracket to rail bolts and remove the upper bracket and rubber mounts.
22. Remove the radiator degas hose to radiator clamp and remove the degas hose.
23. Using a piece of wire or a plastic tie, support the condenser from the upper rail.

Important: Do not open up the A/C system.

24. Remove the condenser block to radiator end tank bolt.
25. Remove the condenser to radiator bolts.
26. Pull the condenser and the pusher fan assembly down slightly to disengage the tabs from the radiator.
27. Leaving the condenser and pusher fan in the vehicle, remove the radiator from the vehicle.
28. Remove the upper and the lower radiator to the condenser gaskets.

### Installation Procedure

1. Install the upper radiator to the condenser gasket on the radiator.
2. Install the radiator lower mounting pins into the rubber mounts.
3. Install the radiator degas hose to the radiator end tank and position the clamp at 1 o'clock.
4. Install the wiring clips to the upper radiator mounting bracket.
5. Position the upper radiator mounts over the upper pins and install the radiator bracket to the rail bolts.

Tighten
Tighten the radiator bracket-to-rail bolts to 6 N·m (53 lb in).

6. Install the wiring clips to the upper radiator mount bracket.
7. Position the condenser tabs under the radiator tabs and install the condenser to radiator bolts.

Tighten
Tighten the condenser-to-radiator bolts to 4 N·m (35 lb in).

8. Install the lower radiator to the condenser gasket.
9. Install the condenser block to radiator end tank bolt.

Tighten
Tighten the condenser block-to-radiator end tank bolt to 4 N·m (35 lb in).

10. Remove the condenser support wire or the plastic tie.
11. Remove the cap and install the lower transaxle cooler line to radiator end tank.

Tighten
Tighten the lower transaxle cooler line-to-radiator end tank to 4 N·m (35 lb in).

Important: The white line on the hose should be installed at the 12 o'clock position.

12. Install the lower radiator hose to the radiator fitting.
13. Install the clamp at the 11 o'clock position.
14. Install the forward wiring harness into the forward rail clips.
15. Install the fan and shroud assembly onto the radiator lower tabs.

Important: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.

16. Install the fan shroud to radiator bolts.

Tighten
Tighten the fan shroud-to-radiator bolts to 4 N·m (35 lb in).

17. Install the upper transaxle oil cooler line into the radiator end tank retainer.
18. Remove the cap and install the upper transaxle oil cooler line to radiator end tank.

Tighten
Tighten the upper transaxle cooler line-to-radiator end tank to 25 N·m (18 lb ft).

19. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
20. Install the fan electrical connectors into the connector retainers as shown.
21. Connect both fan electrical connectors.
22. Install the pusher fan harness under the routing tabs on the fan shroud.
23. Install the upper radiator hose to the radiator end tank and position the clamp at the 12 o'clock position.
24. Install the power steering fluid reservoir to fan shroud bolts.

Tighten
Tighten the power steering reservoir-to-fan shroud bolts to 5 N·m (44 lb in).

25. Verify the battery tray is clean.
26. Install the battery.
27. Install the battery hold down/fan control module bracket.

Tighten
Tighten the battery hold down bracket to 20 N·m (15 lb ft).

Notice: Battery life is reduced if a battery insulation cover is not used.

28. Install the battery insulating cover.
29. Install the fan control module by sliding down onto the bracket.
30. Connect the positive battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

31. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

32. Fill the cooling system. Refer to Coolant Replacement .
33. Use fresh water to rinse away any coolant that was spilled during the service.