For 1990-2009 cars

## Radiator Replacement L61

### Removal Procedure

1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
2. Drain the coolant. Refer to Cooling System Draining and Filling .
3. Disconnect the 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. Remove the upper transaxle cooler line from the radiator.
8. Cap or tape off the cooler line to prevent oil loss or contamination.
9. Remove the upper cooler line from the radiator end tank clip.
10. Remove the upper radiator hose clamp.
11. Remove the upper radiator hose from the radiator.
12. Remove the fan shroud bolts from the radiator.
13. Remove the fan shroud from the radiator.
14. Remove the forward wiring harness from the retaining clips.
15. Remove the lower radiator hose clamp.
16. Remove the lower radiator hose from the radiator.
17. Remove the lower transmission cooler line from the radiator.
18. Cap or tape the cooler line and the end tank to prevent oil spillage or contamination.
19. Remove the radiator upper mount bracket bolts.
20. Remove the radiator upper mount bracket and rubber mounts.
21. Using a piece of wire or a plastic tie, support the condenser to the upper rail.
22. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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

23. Remove the condenser block bolt from the radiator end tank.
24. Remove the condenser hose bolt from the condenser (right side).
25. Remove the condenser bolts from the radiator.
26. Pull the condenser and the pusher fan assembly down slightly to disengage the tabs from the radiator.
27. Lower the vehicle.
28. Leaving the condenser and the pusher fan in the vehicle, remove the radiator from the vehicle.
29. Remove the upper radiator to condenser gaskets.

### Installation Procedure

1. Install the gasket between the upper radiator and the condenser.
2. Install the radiator lower mounting pins to the rubber mounts.
3. Position the upper radiator mounts over the upper pins.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the bolts which secure the radiator bracket to the rail.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

5. Raise the vehicle.
6. Position the condenser tabs under the radiator tabs and install the bolts which secure the condenser to the radiator.

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

7. Install the gasket between the lower radiator and the condenser.
8. Install the bolt which secures the condenser hose clamp to the condenser.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

9. Install the bolt which secures the condenser block to the radiator end tank .

Tighten
Tighten the bolt to 4 N·m (35 lb in).

10. Lower the vehicle.
11. Remove the cap from the lower transmission cooler line.
12. Install the lower transmission cooler line to the radiator end tank.

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

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

13. Install the lower radiator hose to the radiator.

Install the clamp to the 11 o'clock position.

14. Remove the condenser support wire or plastic tie.
15. 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.

16. Install the fan shroud bolts to the radiator.

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

17. Remove the cap from the upper transmission oil cooler line.

Install the line into the end tank retainer and snap into place.

18. Install the upper transmission cooler line to radiator.

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

19. Install the forward wiring harness into the retaining clamps.
20. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
21. Install the fan electrical connectors into the connector retainers as shown.
22. Connect the fan electrical connectors.
23. Install the wiring harness into the shroud retaining clamp.
24. Install the pusher fan harness into the routing tabs on the fan shroud.
25. Install the upper radiator hose to the radiator.
26. Install the upper radiator hose clamp to 12 o'clock position.
27. Install the battery. Refer to Battery Replacement in Engine Electrical.

## Radiator Replacement L81

### Removal Procedure

1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
2. Drain the coolant. Refer to Cooling System Draining and Filling .
3. Remove the bolts which secure the power steering fluid reservoir to the fan shroud.
4. Position the reservoir rearward in the car.
5. Disconnect both of the cooling fan electrical connectors.
6. Remove the electrical connectors from the connector retainer by sliding the connector as shown.
7. Remove the pusher fan electrical harness from the fan shroud retainer tabs.
8. Remove the upper transaxle cooler line from the radiator end tank and unsnap the front end tank retainer.
9. Cap or tape off the cooler line to prevent oil loss or contamination.
10. Remove the clamp which secures the upper radiator hose to the radiator.
11. Remove the upper radiator hose from the radiator.
12. Remove the fan shroud bolts.
13. Remove the fan shroud from the radiator.
14. Remove the forward wiring harness from the retaining clips.
15. Remove the lower radiator hose clamp.
16. Remove the hose from the radiator.
17. Remove the lower transaxle cooler line from the radiator.
18. Cap or tape the cooler line and the end tank to prevent oil spillage or contamination.
19. Remove the wiring harness clips from the upper radiator mounting bracket.
20. Remove the bolts from the radiator upper mount bracket.
21. Remove the bracket and the rubber mounts.
22. Remove the clamp from the radiator coolant air bleed hose.
23. Remove the hose from the radiator.
24. 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.

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

### Installation Procedure

1. Install the gaskets between the upper and lower radiator and the condenser.
2. Install the radiator lower mounting pins into the rubber mounts.
3. Install the radiator coolant air bleed hose to the radiator.
4. Install the radiator coolant air bleed hose clamp at the 1 o'clock position.
5. Install the wiring clips to the upper radiator mounting bracket.
6. Position the upper radiator mounts over the upper pins.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the radiator bracket bolts

Tighten
Tighten the bolts to 6 N·m (53 lb in).

8. Install the wiring clips to the upper radiator mount bracket.
9. Position the condenser tabs under the radiator tabs.
10. Install the condenser to radiator bolts.

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

11. Install the lower radiator to the condenser gasket.
12. Install the bolt which secures the condenser block to the radiator end tank.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

13. Remove the condenser support wire or the plastic tie.
14. Remove the cap and install the lower transaxle cooler line to radiator.

Tighten
Tighten the cooler line to 4 N·m (35 lb in).

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

15. Install the lower radiator hose to the radiator.

Install the clamp at the 11 o'clock position.

16. Install the forward wiring harness into the forward rail clips.
17. 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.

18. Install the bolts that secure the fan shroud to the radiator.

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

19. Install the upper transaxle oil cooler line into the radiator end tank retainer.
20. Remove the cap from the oil cooler line.
21. Install the oil cooler line to the radiator.

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

22. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
23. Install the fan electrical connectors to the connector retainers as shown.
24. Connect the fan electrical connectors.
25. Install the pusher fan harness under the routing tabs on the fan shroud.
26. Install the upper radiator hose to the radiator.

Install the clamp to the 12 o'clock position.

27. Install the bolts which secure the power steering fluid reservoir to the fan shroud.

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

28. Install the battery. Refer to Battery Replacement in Engine Electrical.
29. Install the fan control module by sliding down onto the bracket.
30. Fill the cooling system. Refer to Cooling System Draining and Filling .