For 1990-2009 cars

## Radiator Replacement 2.0L Diesel LLW

### Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
2. Remove the radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement.
3. Remove the hood primary and secondary latch. Refer to Hood Primary and Secondary Latch Replacement.
4. Remove the intake air duct. Refer to Intake Air Duct Replacement.
5. Drain the cooling system. Refer to Cooling System Draining and Filling.
6. Remove the cooling lines. Refer to Radiator Inlet Hose Replacement and Radiator Outlet Hose Replacement.
7. Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement.
8. Remove the charge air cooler. Refer to Charge Air Cooler Replacement.
9. Remove the engine coolant fan. Refer to Engine Coolant Fan Replacement.
10. Remove the air conditioning condensor. Refer to Air Conditioning Condenser Replacement.
11. Remove the radiator air seal (1).
12. Remove the radiator (1).

### Installation Procedure

1. Install the radiator (1).
2. Install the radiator air seal (1)
3. Install the air conditioning condensor. Refer to Air Conditioning Condenser Replacement.
4. Install the engine coolant fan. Refer to Engine Coolant Fan Replacement.
5. Install the charge air cooler. Refer to Charge Air Cooler Replacement.
6. Install the radiator support brackets. Refer to Radiator Support Bracket Replacement.
7. Install the cooling lines. Refer to Radiator Inlet Hose Replacement and Radiator Outlet Hose Replacement.
8. Fill the cooling system. Refer to Cooling System Draining and Filling.
9. Install the intake air duct. Refer to Intake Air Duct Replacement.
10. Install the hood primary and secondary latch. Refer to Hood Primary and Secondary Latch Replacement.
11. Install the radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement.
12. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.

## Radiator Replacement 1.6L LXV

### Removal Procedure

1. Open the hood.
2. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement.
4. Remove the front bumper facia. Refer to Front Bumper Fascia Replacement.
5. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement.
6. Remove the hood primary and secondary latch. Refer to Hood Primary and Secondary Latch Replacement.
7. Drain the cooling system. Refer to Cooling System Draining and Filling.
8. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
9. Loosen the radiator outlet hose clamp (5).
10. Remove the radiator outlet hose (3) from the radiator outlet pipe (4).
11. Loosen the radiator inlet hose clamp (2).
12. Remove the radiator inlet hose (3) from the radiator (1).
13. For vehicle with automatic transmission:

• | Drain the transmission fluid. Refer to Transmission Fluid Replacement.

• | Remove the transmission fluid cooler outlet pipe from the radiator. Refer to Transmission Fluid Cooler Outlet Pipe Replacement.

• | Remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement.

14. Lower the vehicle by its full height.

Note: Do not remove radiator fan.

15. Unclip the radiator fan from the radiator. Refer to Engine Coolant Fan Replacement.
16. Unclip the radiator outlet hose from the radiator.

Note: Do not remove the condensor. Lift the condensor straight up high as much as required.

17. Unclip the condensor (1) from the radiator.
18. Remove the 2 radiator bolts (1).
19. Remove the radiator upper bracket (2).
20. Radiator upper insulator (3).
21. Remove the radiator (4).

### Installation Procedure

1. Install the radiator (4).
2. Install radiator upper insulator (3).
3. Install the radiator upper bracket (2).

Caution: Refer to Fastener Caution in the Preface section.

4. Install the 2 radiator bolts (1) and tighten to 22 N·m (17 lb ft).
5. Clip the condensor (1) to the radiator.
6. Clip the radiator fan to the radiator. Refer to Engine Coolant Fan Replacement.
7. Clip the radiator outlet hose into the radiator.
8. Raise the vehicle by its full height.
9. For vehicle with automatic transmission:

• | Fill the transmission fluid. Refer to Transmission Fluid Replacement.

• | Install the transmission fluid cooler outlet pipe to the radiator. Refer to Transmission Fluid Cooler Outlet Pipe Replacement.

• | Install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement.

10. Install the radiator inlet hose (3) to the radiator (1).
11. Install the radiator inlet hose clamp (2).
12. Install the radiator outlet hose (3) to the radiator outlet pipe (4).
13. Install the radiator outlet hose clamp (5).
14. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
15. Fill the cooling system. Refer to Cooling System Draining and Filling.
16. Install the hood primary and secondary latch. Refer to Hood Primary and Secondary Latch Replacement.
17. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement.
18. Install the front bumper facia. Refer to Front Bumper Fascia Replacement.
19. Install the radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement.
20. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection.
21. Close the hood.