Radiator and Fan Replacement

1.Drain engine coolant.

2.Remove the front grille cover.

3.Remove the splash shield.

 

4.Disconnect the hood switch connector (A), and remove the harness clamps (B).

 

5.Remove the radiator upper bracket mounting bolts (A), A/C condenser bracket mounting bolts (B), and intercooler bracket mounting bolt (C), then remove the bulkhead (D).

 

6.Remove the A/C condenser brackets (A) and radiator upper brackets/cushions (B).

 

7.Clean any dirt off the quick connector (A), radiator, and upper radiator hose.

 

8.Pull out the lock (B) by hand, then wiggle the quick connector loose, and remove it from the radiator. Do not use any tools to remove the quick connector.

9.Clean any dirt off the quick connector (A), radiator, and lower radiator hose.

 

10.Pull out the lock (B) by hand, then wiggle the quick connector loose, and remove it from the radiator. Do not use any tools to remove the quick connector.

11.Disconnect the A/C condenser fan motor connector (A) and radiator fan motor connector (B), then remove the A/C compressor clutch connector (C) and water bypass pipe (D) from the A/C condenser fan shroud.

 

12.Remove the two bolts (E), and loosen the two bolts (F) securing the A/C condenser fan shroud, then remove the A/C condenser fan shroud assembly (G).

13.Remove the two bolts (H), and loosen the two bolts (I) securing the radiator fan shroud, then remove the radiator fan shroud assembly (J).

14.Disconnect the radiator fan switch (Low) connector (A), and remove the water bypass hoses (B).

 

15.Pull up the radiator (C), then remove radiator fan switch (Low) (D) and drain plug (E).

16.Install the radiator fan switch (Low) and drain plug with new O-rings (F), then install the radiator in the reverse order of removal. Make sure the lower cushions (G) are set securely.

17.Install the radiator fan shroud, then install the A/C condenser fan shroud.

18.Install the A/C compressor clutch connector and water bypass pipe on the A/C condenser fan shroud, then connect the A/C condenser fan motor connector and radiator fan motor connector.

19.Check the quick connector (A) and set ring (B) for cracks or damage. If the connector and/or set ring are cracked or damaged, replace the connector.

 

20.Make sure the set ring is in place inside the quick connector. If the set ring is off the connector, replace the quick connector.

21.Replace the O-ring (C) in the quick connector.

22.Check the lock (D). If the lock is damaged or deformed, replace it. When installing the new lock on the connector, press it straight down along the groove.

23.Clean the connecting surfaces of the radiator (E), then apply clean engine coolant around the connecting surfaces.

24.Push down the lock (A), then push the quick connector (B) onto the radiator until you hear it click.

 

25.Push down the lock (A), then push the quick connector (B) onto the radiator until you hear it click.

 

26.Install the A/C condenser brackets and radiator upper brackets/cushions.

27.Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.

28.Connect the hood switch connector, and install the harness clamps.

29.Install the splash shield.

30.Install the front grille cover.

31.Refill the expansion tank with engine coolant, and bleed air from the cooling system with the heater valve open.