Chrysler Neon 1995-1999 Repair Guide

Radiator

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REMOVAL & INSTALLATION



See Figures 1 through 15

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Never remove the cylinder block plug or the radiator draincock with the system hot and under pressure, as serious burns could occur.

  1. Drain the cooling system into a suitable container.
  2.  
  3. Remove the engine air inlet duct.
  4.  
  5. Disconnect the upper radiator hose from the radiator.
  6.  



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Fig. Fig. 1: Use pliers to unfasten the clamps, then disconnect the upper radiator hose

  1. If equipped with automatic transaxle, disconnect and plug the transaxle oil cooler lines from the radiator or the transaxle, as necessary.
  2.  



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Fig. Fig. 2: If you disconnect the cooler lines from the transaxle, you will spill less coolant

  1. Remove the radiator-to-battery strut and ground strap.
  2.  



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Fig. Fig. 3: Remove the radiator-to-battery strut (1) and ground strap (2)

  1. If equipped with dual fans, remove the battery and battery tray.
  2.  



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Fig. Fig. 4: Remove the battery, unfasten the retainers, then remove the battery tray

Be careful not to damage the fan module(s) during removal.

  1. Remove the fan module assembly, as follows:
    1. Detach the fan motor electrical connector.
    2.  
    3. Remove the fan shroud retaining screws, located on top of the shroud. Lift the shroud up and out of the bottom shroud attaching clips separating the shroud from the radiator.
    4.  
    5. For vehicles with dual fans, remove the left side fan first, then remove the right side module last.

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      Fig. Fig. 5: Unplug the first fan motor electrical connector ...



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      Fig. Fig. 6: ... then unplug the other fan connector



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      Fig. Fig. 7: Unfasten the fan mounting bolts ...



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      Fig. Fig. 8: ... then remove the left side fan ...



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      Fig. Fig. 9: ... and the right side fan from the vehicle

    6.  

  2.  
  3. Disconnect the lower radiator hose.
  4.  



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Fig. Fig. 10: Unfasten the hose clamp, then disconnect the lower radiator hose

  1. Remove the upper radiator isolator bracket mounting screws. If equipped, disconnect the engine block heater wire.
  2.  



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Fig. Fig. 11: Location of the upper radiator mounts



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Fig. Fig. 12: Remove the upper radiator mounting bolts

  1. If equipped with A/C, remove the condenser attaching screws (located at the front of the radiator), then lean the condenser forward.
  2.  



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Fig. Fig. 13: If equipped with A/C, unfasten the condenser mounting screws



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Fig. Fig. 14: You can access the condenser mounting bolts at the front of the radiator

It is not necessary to have the A/C system discharged to remove the radiator.

  1. You can not lift the radiator free from the engine compartment. Be very careful not the damage the radiator cooling fins or water tubes during removal.
  2.  



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Fig. Fig. 15: Carefully lift the radiator from the engine compartment

To install:
  1. Slide the radiator down into position behind the radiator support (yoke).
  2.  
  3. If equipped, attach the A/C condenser to the radiator with the 4 mounting screws and tighten to 50 inch lbs. (5.4 Nm). Then, seat the assembly lower rubber isolators into the mounting holes provided in the lower crossmember.
  4.  
  5. Tighten the radiator isolator mounting bracket screws to 90 inch lbs. (10 Nm). The radiator should have clearance to move upward about 0.25 in. (5-8mm) after installed.
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  7. Connect the lower radiator hose, making sure to align the hose and position the clamp so it will not interfere with any other engine components.
  8.  
  9. If equipped, unplug and connect the automatic transmission hoses. Tighten the hose clamps to 35 inch lbs. (4 Nm).
  10.  
  11. Slide the fan module down into the clip(s) on the lower radiator flange. For vehicles with dual fans, install the right fan module first, then install the left fan module. Install the retaining screws and tighten to 65 inch lbs. (7.5 Nm).
  12.  
  13. Attach the cooling fan electrical connector.
  14.  
  15. Connect the upper radiator hose. Make sure the hose is aligned and position the clamp so it will not interfere with other engine components.
  16.  
  17. If equipped with dual fans, install the battery tray and battery. Connect the positive battery cable.
  18.  
  19. Connect the negative battery cable. Make sure the draincock is closed and all block plugs are installed, then fill the cooling system with the proper type and amount of coolant.
  20.  
  21. Start the engine and allow it to reach normal operating temperatures. Check the coolant system and automatic transaxle for proper fluid levels. Add as necessary.
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