REMOVAL & INSTALLATION
Sebring Coupe and Avenger
See Figure 1
The radiator is the corrugated fin, downflow type, and is cooled by electric radiator fans. Service the cooling system with high quality ethylene glycol or other aluminum compatible antifreeze coolant.
- Disconnect the negative battery cable.
- Loosen the radiator drain plug and, using a large capacity container, drain the cooling system.
- Remove the radiator cap.
- If necessary for clearance, remove the bracket and plastic branch tube running from the air cleaner.
- Disconnect the overflow tube and remove the coolant reserve tank.
- Disconnect the upper radiator hose.
It is recommended that each clamp be matchmarked to the hose. Observe the marks and reinstall the clamps in exactly the same position when reinstalling the radiator.
- Label and disengage the wiring to the thermosensors and the electric fan assemblies.
- For vehicles with automatic transaxles, disconnect the oil cooler lines at the radiator. Plug the transaxle ports and the hose ends to contain the fluid and prevent contamination.
- Remove the lower radiator hose.
- Remove the bolts holding the upper mounting brackets to the support member. Remove the radiator, with the cooling fans as an assembly.
- If the fan and shroud assemblies were removed with the radiator, they must be reinstalled before installing the radiator. The mounting bolts for the fans should be tightened to 10 ft. lbs. (14 Nm). If the thermosensors were removed, they should be reinstalled and tightened to 10 ft. lbs. (14 Nm).
- Reinstall the radiator, making certain all the mounts and bushings are correctly positioned. Tighten the mounting bolts to 10 ft. lbs. (14 Nm). Double check the drain plug to make sure it is closed.
- Connect the oil cooler lines and attach the brackets.
- Connect the wiring to the electrical components, making sure each is correctly located and securely fastened.
- Connect the upper and lower radiator hoses and the overflow hose. Install the coolant reserve tank.
- Install the branch tube and its bracket.
- Fill the system with coolant.
- Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely and check the automatic transaxle fluid level, if equipped.
- Allow the engine to warm up fully and check that the fans cycle on and off correctly. Watch the coolant level carefully in the overflow tank.
- Once the vehicle has cooled, recheck the coolant level.
Cirrus, Sebring Convertible, Stratus and Breeze
See Figures 2 through 15
The radiator uses plastic tanks. Plastic tanks, while stronger than brass, are subject to damage by impact, such as slipped wrenches. Use care when working around these radiators.
- Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
- Remove the air inlet resonator.
- Place a large drain pan under the radiator drain plug. Drain and properly contain engine coolant.
To open the drain plug on models equipped with a 2.5L engine, use a3/8inch drive extension 3 inches (7.6cm) long and a 19mm socket with universal joint. The drain plug can also be accessed by removing the right front fog light in the front lower bumper fascia.
Remove the upper radiator crossmember as follows:
- Remove the push-in mounting fasteners securing the front fascia/grille unit to the radiator support crossmember.
- Remove the mounting bolts securing the support braces to the bottom of the crossmember.
- Remove the bolts securing the crossmember to the radiator closure panel.
- Remove the mounting nuts attaching the hood latch to the radiator crossmember. Remove the crossmember from the vehicle.
The following step and associated photos describe original type hose clamps. Some vehicles may instead have a worm gear type clamp, which can be loosened with a screwdriver.
- Using pliers, compress the tabs on each hose clamp, then slide the clamp a few inches away from the hose end. Carefully twist and pull the hoses from the radiator.
- Disconnect the engine block heater wire, if equipped.
- Disconnect and plug the transaxle cooler lines, if equipped.
- Remove screw attaching support bracket for external transaxle cooler lines to the left side of the radiator, if equipped.
- Remove the screw attaching the support bracket for air conditioning lines from the right side of the radiator. Remove the support bracket.
- Unplug the cooling fan wiring.
- Remove the air conditioning condenser mounting screws. Use care when working around the air conditioning condenser. Avoid bending the condenser inlet tube. Care should be taken not to damage the radiator or condenser cooling fins or water tubes during removal. It is not necessary to discharge the air conditioning system to remove the radiator.
- Carefully remove the radiator from the vehicle. The cooling fan/shroud assembly can be separated from the radiator at this time.
- If separated, install the cooling fan/shroud assembly to the radiator unit.
- Lower the radiator and fan module (assembly) into position. Seat the radiator assembly lower isolators in the mount holes provided.
- Install the air conditioning condenser mounting screws and tighten to 45 inch lbs. (5 Nm).
- Connect the radiator hoses and tighten the hose clamps to 22 inch lbs. (2.5 Nm). Be sure the hoses do not interfere with the accessory drive belt, and be sure the upper hose clamp does not interfere with the hood liner.
- Connect the cooling fan wiring.
- Connect the transaxle cooler lines to the radiator, if equipped.
Install the upper radiator crossmember as follows:
- Place the radiator crossmember into the vehicle in proper position.
- Install the hood latch to the radiator crossmember. Install and tighten the hood latch mounting nuts.
- Install and tighten the crossmember-to-radiator closure panel mounting bolts.
- Install and tighten the mounting bolts that secure the support braces to bottom of the radiator crossmember.
- Install the push-in mounting fasteners holding the front fascia/grille unit to the radiator crossmember.
- Connect the engine block heater, if equipped.
- Install the air inlet resonator.
- Fill the cooling system with the correct type and amount of engine coolant.
- Reconnect the negative battery cable. Start the engine and allow it to idle until it reaches full operating temperature. Check the cooling system for correct fluid level and top off if necessary.