Engine - 1.6L SOHC: Radiator: Removal

WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

NOTE: It is not necessary to discharge the air conditioning system to remove the radiator.

1. Disconnect negative cable from battery.
2. Raise vehicle on hoist.
3. Drain the cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .
4. Disconnect radiator fan motor electrical connector. See Fig 1.
   Fig 1: Cooling Module

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - UPPER RADIATOR CROSSMEMBER

   2 - COOLING MODULE

   3 - RADIATOR FAN CONNECTOR

   4 - LOWER RADIATOR CROSSMEMBER

5. Disconnect lower radiator hose.
6. Remove two lower fasteners attaching radiator fan shroud to radiator. See Fig 2.
   Fig 2: Radiator Fan - Mounting

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - RADIATOR FAN SHROUD

   2 - SCREWS

   3 - SCREWS

7. Dislodge lower radiator air seal from side radiator air seals. See Fig 3.
   Fig 3: Air Seals

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - A/C CONDENSER

   2 - SIDE AIR SEALS

   3 - LOWER AIR SEAL

8. Lower vehicle.
9. Remove grille (Refer to BODY/EXTERIOR/GRILLE - REMOVAL) .
10. Remove upper radiator closure panel (Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL - REMOVAL) .
11. Disconnect upper radiator hose and overflow hose from the radiator filler neck. See Fig 4.
12. Remove remaining fasteners attaching radiator fan shroud to radiator. See Fig 2.
13. Remove radiator fan/shroud assembly.
14. Remove remaining fasteners attaching AC condenser to radiator. Reposition AC condenser.
15. Remove radiator assembly by lifting it up from the engine compartment. Care should be taken not to damage the cooling fins and tubes during removal. 
16. Remove the lower air seal from radiator. See Fig 3.

Fig 4: Radiator

Courtesy of DAIMLERCHRYSLER CORP.

1 - OVERFLOW HOSE

2 - UPPER RADIATOR HOSE

3 - RADIATOR ASSEMBLY