Removal
Models without air conditioning
1. Remove the ground cable from the battery.
2. Raise the front of the vehicle and support it on stands.
3. Drain the coolant from the cooling system by disconnecting the hose from the base of the radiator.
4. Remove the radiator fan assembly from the rear of the radiator.
5. Disconnect the expansion tank hose and, if present, remove the small thermostat hose from the top of the radiator.
6. Remove the upper hose from the left side of the radiator.
7. On models with automatic transmission, disconnect the hoses from the heat exchanger.
8. Disconnect the electrical connectors from the radiator fan.
9. Disconnect the electrical connectors from the fan thermal switch (indicated by the arrow).
10. Release the electrical wires from the top of the radiator.
11. Remove the radiator grille.
12. If equipped, remove the air runners from the left and right sides of the radiator and the power steering heat exchanger hose.
13. On 2.0L diesel models, remove the power steering reservoir mounting bolt from the top of the radiator.
14. Remove the power steering heat exchanger hose.
15. Unscrew the bolts and remove the upper radiator hanger.
16. Remove the upper radiator mounts.
17. Remove the rubber damper from the upper radiator mount.
18. Remove the radiator (photo on the left), lifting it up from the rubber pads in the lower frame (the location of the radiator rubber cushion in the front lower frame is indicated by the arrow in the photo on the right). Remove the radiator from the engine compartment.
Models with air conditioning
19. Remove the ground cable from the battery.
20. Raise the front of the vehicle and support it on stands.
21. Drain the coolant by disconnecting the lower radiator hose.
22. Remove the electric radiator fan assembly from the rear of the radiator.
23. Disconnect the expansion tank hose and remove the small thermostat hose from the top of the radiator.
24. Remove the upper hose from the left side of the radiator.
25. On models with automatic transmission, disconnect the hoses from the heat exchanger.
26. Disconnect the electrical connector from the cooling fan and fan thermostat switch. Also disconnect the electrical connector from the air conditioning thermostat switch.
27. Remove the front bumper.
28. Remove the air conditioning condenser and auxiliary electric fan mounting bolts from the front of the radiator and move them to the side without disconnecting the hoses from them.
29. If necessary, unscrew the evaporator mounting bolt.
30. On diesel engines with a heat exchanger, remove the air supply pipe.
31. Remove the bolts and remove the upper radiator hangers, then lift the radiator up out of the lower rubber mounts.
Examination
1. If the radiator was removed due to reduced throughput, flush it with a stream of water in both directions. Blow the radiator out with compressed air from the outside.
2. If the radiator is leaking, do not try to weld or solder the leak, as this will damage the plastic parts of the radiator.
3. Minor radiator leaks can be repaired using radiator sealant.
4. Check the condition of the lower radiator rubber mounts and replace them if necessary.
Installation
Installation is carried out in the reverse order of removal, taking into account the following points:
- check that the lower tabs on the radiator are installed in the rubber supports;
- check that all hoses are properly connected and securely fastened with clamps;
- finally, fill the cooling system with coolant.
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