Radiator and coolant expansion tank — removal and installation …
Warning: Do not start this procedure until the engine is completely cool.
Warning: Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Antifreeze is highly toxic if ingested. Never leave antifreeze lying around in an open container or in puddles on the floor; children and pets are attracted by its sweet smell and may drink it. Check with local authorities about disposing of used antifreeze. Many communities have collection centers which will see that antifreeze is disposed of safely. Never dump used antifreeze on the drains.
Warning: The air conditioning system is under high pressure. Do not loosen any hose fittings or remove any components until the system has been discharged. Air conditioning refrigerant should be properly discharged into an EPA-approved recovery/recycling unit by a dealer service department or an automotive air conditioning repair facility. Always wear eye protection when disconnecting air conditioning system fittings.
Note: Non-toxic coolant is available at local auto parts stores. Although the coolant is nontoxic when fresh, proper disposal of used coolant is still required.
Radiator
1. Have the refrigerant discharged by an automotive air conditioning technician.
2. Disconnect the cable from the negative battery terminal, then remove the battery hold-down clamp (see Engine electrical systems).
3. Remove the front bumper cover (see Body) and the headlight housings (see Chassis electrical system).
4. Drain the cooling system (see Tune-up and routine maintenance).
5. Remove the hood latch, then detach the
hood release cable from the clips along the radiator support (see Body).
6. Disengage the radiator air deflector clips and remove the air deflector from the top of the radiator.
7. Disconnect the electrical connectors to the horns (see Chassis electrical system) then remove the front bumper upper support reinforcement bolts and remove the support along with the horns as an assembly.
8. Disconnect the inlet and outlet lines to the condenser (see Troubleshooting). Cap the open fittings immediately to keep moisture and dirt out of the system.
9. Unclip the cooling fan wiring harness along the fan housing, then disconnect the electrical connectors from the cooling fans (see illustration).
i. 9 Unclip the cooling fan wiring harness and disconnect the electrical connectors to the cooling fans
10. Remove the bolts from the radiator mounting brackets and remove the brackets (see illustration).
i. 10 Radiator mounting bracket and radiator support fastener locations
11. Remove the four upper radiator support mounting bolts and remove the upper radiator support.
12. Depress the locking tabs and disconnect the by-pass hoses from the radiator
hose assembly.
13. Squeeze the clamps and slide them back on the hoses, then disconnect the upper and lower radiator hoses from the radiator.
14. Disconnect the expansion tank hoses from the radiator (see illustration).
i. 14 Disconnect the reservoir hoses from the radiator
15. Lift out the radiator and fan and condenser assembly. Be aware of dripping fluids and the sharp fins.
16. Remove the oil cooler tube clips and bolts from the fan shroud.
17. Remove the fan shroud support mounting bolts and separate the support from the top of the fan shroud.
18. Remove the air conditioning condenser, then remove the radiator from the shroud.
19. With the radiator removed, it can be inspected for leaks, damage and internal blockage.
20. If in need of repairs, have a professional radiator shop or dealer service department perform the work, as special techniques are required.
21. Bugs and dirt can be cleaned from the radiator with compressed air and a soft brush. Don’t bend the cooling fins as this is done.
Warning: Wear eye protection.
22. Installation is the reverse of removal. Be sure the rubber mounts are in place.
23. After installation, fill the cooling system with the proper mixture of antifreeze and water (see Tune-up and routine maintenance).
24. Have the air conditioning system evacuated, charged and leak tested by the shop that discharged it. If the condenser or receiver/ drier was replaced, have them add the proper amount of refrigeration oil to the compressor. Use only compressor oil compatible with R-134a refrigerant.
Coolant reservoir/expansion tank
25. Drain the cooling system until the level has dropped below the expansion tank (see Tune-up and routine maintenance), then disconnect the hoses from the tank and remove the tank mounting fasteners (see illustration).
i. 25 Coolant expansion tank (A), mounting fasteners (B) and hoses (C)
26. Installation is the reverse of removal. Refill the cooling system (see Tune-up and routine maintenance).