ION 2006-2007

Removal & Installation

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2.0L Engine



  1. Disconnect the cooling fan electrical connectors.

    Click image to see an enlarged view

    Fig. Disconnect the fan relays from the shroud

  2.  
  3. Disconnect the fan relays from the shroud.
  4.  
  5. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cooling fan assembly from the radiator

  6.  
  7. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator.
  8.  
  9. Remove the air dam push-in retainers.
  10.  
  11. Remove the air dam.
  12.  
  13. Remove the right engine splash shield to radiator mount push-in retainer.
  14.  
  15. Remove the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. Remove the charge air cooler radiator.

    Click image to see an enlarged view

    Fig. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser

  18.  
  19. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  20.  
  21. Tilt the radiator and condenser forward in the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cooling fan assembly from the vehicle

  22.  
  23. Remove the cooling fan assembly from the vehicle.
  24.  

To install:

  1. Install the cooling fan assembly into the vehicle.
  2.  
  3. Restore the radiator and condenser to the original position.
  4.  
  5. Install the charge air cooler radiator.
  6.  
  7. Verify that the upper radiator mounts are installed in the vehicle.
  8.  
  9. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  10.  
  11. Install the lower radiator mounts, brackets, and bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the right engine splash shield to radiator mount push-in retainer.
  14.  
  15. Install the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. Install the air dam and the push-in retainers.
  18.  
  19. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator.
  20.  
  21. Lower the vehicle.
  22.  
  23. Connect the cooling fan electrical connectors.
  24.  
  25. Connect the fan relays to the fan shroud.
  26.  

2.2L & 2.4L Engines



  1. Disconnect the cooling fan electrical connector.
  2.  
  3. Remove the cooling fan wire from the fan shroud.
  4.  
  5. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cooling fan assembly from the radiator

  6.  
  7. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator.
  8.  
  9. Remove the air dam push-in retainers.

    Click image to see an enlarged view

    Fig. Remove the air dam

  10.  
  11. Remove the air dam.

    Click image to see an enlarged view

    Fig. Remove the right engine splash shield to radiator mount push-in retainer

  12.  
  13. Remove the right engine splash shield to radiator mount push-in retainer.
  14.  
  15. Remove the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  18.  
  19. Tilt the radiator and condenser forward in the vehicle. Remove the cooling fan assembly from the vehicle.
  20.  

To install:

  1. Tilt the radiator and condenser forward in the vehicle. Install the cooling fan assembly into the vehicle.
  2.  
  3. Verify that the upper radiator mounts are installed in the vehicle.
  4.  
  5. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  6.  
  7. Install the lower radiator mounts, brackets, and bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the right engine splash shield to radiator mount push-in retainer.
  10.  
  11. Install the left engine splash shield to radiator mount push-in retainer.
  12.  
  13. Install the air dam and the push-in retainers.
  14.  
  15. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the cooling fan electrical connector.
  20.  
  21. Install the cooling fan wire to the fan shroud.
  22.  

 
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