ION, L-Series, S-Series 1999-2005

Removal & Installation

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  1. Drain the cooling system.
  2.  
  3. Lower the vehicle.
  4.  
  5. If vehicle is equipped with the 2.2L (L61) engine, remove the air cleaner outlet resonator.
  6.  
  7. Reposition the radiator inlet hose clamp at the radiator using special tool SA9111E.
  8.  
  9. Remove the radiator inlet hose from the radiator.

    Click image to see an enlarged view

    Fig. Remove the radiator outlet hose from the radiator

  10.  
  11. Reposition the radiator outlet hose clamp at the radiator using special tool SA9111E.
  12.  
  13. Remove the radiator outlet hose from the radiator.
  14.  
  15. If equipped with an automatic transaxle, clean the upper transmission oil cooler line connection point and remove the line from the radiator.
  16.  
  17. If equipped with an automatic transaxle, remove the left front wheelhouse liner.
  18.  
  19. If equipped with an automatic transaxle, remove the left engine splash shield.
  20.  
  21. If equipped with an automatic transaxle, clean the lower transmission oil cooler line connection point and remove the line from the radiator.

    Click image to see an enlarged view

    Fig. Remove the cooling fan assembly from the radiator

  22.  
  23. 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 and support the cooling fan assembly.
  24.  
  25. Remove the air dam push-in retainer.
  26.  
  27. Remove the air dam.
  28.  
  29. If equipped with air conditioning, remove the condenser bolts.
    NOTE
    You are not required to discharge the A/C System.

  30.  
  31. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  32.  
  33. Position the condenser away from the radiator and support the condenser.

    Click image to see an enlarged view

    Fig. Remove the right and left radiator side baffles

  34.  
  35. Remove the right and left radiator side baffles.
  36.  
  37. Remove the right engine splash shield to radiator mount push-in retainer.
  38.  
  39. If equipped with a manual transaxle, remove the left engine splash shield to radiator mount push-in retainer.

    Click image to see an enlarged view

    Fig. Remove the lower radiator mounts, brackets, and bolts

  40.  
  41. Remove the lower radiator mounts, brackets, and bolts.

    Click image to see an enlarged view

    Fig. Tilt the condenser forward in the vehicle. Remove the radiator assembly from the vehicle

  42.  
  43. Tilt the condenser forward in the vehicle. Remove the radiator assembly from the vehicle.
  44.  
  45. Remove the upper radiator air baffle.
  46.  

To install:

  1. Verify that the upper radiator mounts are installed in the vehicle.
  2.  
  3. Install the upper radiator air baffle.
  4.  
  5. Tilt the condenser forward in the vehicle. Install the radiator assembly into the vehicle.
  6.  
  7. Verify that the upper radiator mount pins align with the upper radiator mounts.
  8.  
  9. Install the lower radiator mounts, brackets, and bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the right engine splash shield to radiator mount push-in retainer.
  12.  
  13. If equipped with a manual transaxle, install the left engine splash shield to radiator mount push-in retainer.
  14.  
  15. If equipped with air conditioning, install the right and left radiator side baffles.
  16.  
  17. Slide the condenser up to engage the upper mounting tabs into the radiator.
  18.  
  19. Install the condenser bolts, and tighten the bolts to 89 inch lbs.(10 Nm).
  20.  
  21. Install the air dam and push-in retainers.
  22.  
  23. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.
  24.  
  25. If equipped with an automatic transaxle, install the lower transmission oil cooler line and seal the radiator. Tighten the transmission oil cooler line to 15 ft. lbs. (20 Nm).
  26.  
  27. If equipped with an automatic transaxle, install the left engine splash shield.
  28.  
  29. If equipped with an automatic transaxle, install the left front wheelhouse liner.
  30.  
  31. Lower the vehicle.
  32.  
  33. If equipped with an automatic transaxle, install the upper transmission oil cooler line and seal to the radiator. Tighten the transmission oil cooler line to 15 ft. lbs. (20 Nm).
  34.  
  35. Install the radiator outlet hose to the radiator.
  36.  
  37. Reposition the hose clamp to secure the hose using special tool SA9111E.
  38.  
  39. Install the radiator inlet hose to the radiator.
  40.  
  41. Reposition the hose clamp to secure the hose using special tool SA9111E.
  42.  
  43. If equipped with 2.2L (L61) engine, install the air cleaner outlet resonator.
  44.  
  45. Fill the cooling system.
  46.  
  47. If equipped with an automatic transaxle, add fluid to the transmission as necessary.
  48.  

 
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