Radiator Replacement

For Reference

SL2 Radiator Replacement w/PICS by SATURNFAN Sevillian273

S-Series Radiator Replacement by SATURNFAN RangerRover

richpin06a Radiator Removal Walkthrough

richpin06a Radiator Replacement

Removal Procedure

1. Remove the negative battery terminal.
2. Drain the cooling system. Refer to Engine Coolant Check and Replacement .




3. Remove the air intake duct, air filter box, and resonator.




4. Remove the upper radiator clamp and hose from the radiator and fold the hose back.




5. On models with an automatic transaxles, remove the upper transaxle oil cooler line.




6. Remove the fan motor electrical connector.
7. Remove the wiring harness from the fan shroud and radiator end tank.




8. Lift the coolant fan off of the upper and lower mounting brackets.
9. Remove the fan assembly from the vehicle.





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.

10. Remove the lower radiator clamp and hose from the radiator.
11. Raise the vehicle.




12. Remove the lower splash shield.




13. On models with an automatic transaxle, remove the lower transaxle oil cooler line.





Important

Wire the condenser up to the vehicle to keep in place.

14. Remove the two lower condenser bracket-to-radiator bolts.
15. Lower the vehicle.




16. Remove the upper radiator nuts and brackets.
17. Remove the upper radiator seal.
18. Remove the radiator from the vehicle.

Installation Procedure

1. Install the radiator in the vehicle.
2. Install the upper radiator seal.

Notice

Refer to Fastener Notice in Cautions and Notices.

Important

The L-shaped brackets must not pinch the radiator locating pins. The radiator must be able to move freely in the grommets after installation.

3. Install the upper radiator brackets and nuts.
Tighten

Tighten the radiator support brackets to 10 N·m (89 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. Install the two lower condenser bracket-to-radiator bolts and remove support wire.
Tighten

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





6. On models with an automatic transaxle, install the lower transaxle oil cooler line.
Tighten

Tighten the lower transaxle oil cooler line 14 N·m (10 lb ft).





7. Install the lower splash shield.
8. Lower the vehicle.




9. Install the lower radiator hose and clamp. Position the clamp at 11 o'clock.




10. Install the fan assembly.




11. Install the upper hold down bolt.
Tighten

Tighten the upper hold down bolt to 6 N·m (53 lb in).

12. Install the fan motor electrical connector.
13. Install the wiring harness to the fan shroud and radiator end tank.




14. On vehicles with an automatic transaxle, install and tighten the upper transaxle oil cooler line.
15. Install the upper transaxle oil cooler line at a 35 degree angle to the vertical center line of the radiator end tank and hold while tightening.
Tighten

Tighten the upper transaxle oil cooler line to 14 N·m (10 lb ft).





16. Install the upper radiator hose and clamp. Position the clamp at 1 o'clock.
Tighten

Tighten the upper radiator hose and clamp to 3.5 N·m (31 lb in).





17. Install the air filter box, intake air duct, and resonator.
18. Connect the negative battery terminal.
Tighten

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

19. Fill with coolant and leak test. Refer to Engine Coolant Check and Replacement .