Neon, 2000 - 2005

Removal & Installation (12 of 22)

Print


CAUTION
Do not remove the cylinder block plug or the radiator brainsick with the system hot and under pressure because serious burns from coolant can occur.

  1. Disconnect negative cable from battery.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the radiator upper hose from the radiator.
  6.  
  7. Disconnect the radiator fan motor electrical connector.
  8.  
  9. Remove the radiator fan assembly.
    NOTE
    When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses and clamps must be replaced.

  10.  
  11. Disconnect and cap automatic transmission hoses (if equipped).
  12.  
  13. Remove the radiator lower hose.
  14.  
  15. Remove radiator upper isolator bracket mounting screws. Disconnect the engine block heater wire (if equipped).
  16.  
  17. Remove the A/C condenser attaching screws located at the front of the radiator (if equipped), then lean condenser forward.
    NOTE
    It is not necessary to discharge the air conditioning system to remove the radiator.

  18.  
  19. Radiator can now be lifted free from engine compartment.
    WARNING
    Be careful not to damage radiator cooling fins or water tubes during removal.



    Click image to see an enlarged view

    Fig. Cooler fitting (1), cooler supply hose (2), cooler return hose (3) and cooler fitting (4)



    Click image to see an enlarged view

    Fig. Radiator upper hose (1) and radiator upper mounts (2)



    Click image to see an enlarged view

    Fig. Air conditioning condenser to radiator mounting screws (1) and lower isolator mounts (2)

  20.  

To install:

  1. Install radiator into position behind the radiator support (yoke).
  2.  
  3. Attach A/C condenser to radiator (if equipped), with four mounting screws. Tighten screws to 65 inch lbs.( 7.2 Nm). Then seat the radiator assembly lower rubber isolators into the mounting holes provided in the lower crossmember.
  4.  
  5. Install and tighten radiator isolator mounting bracket screws to 90 inch lbs. (10 Nm). The radiator should have clearance to move up, approximately 0.20-0.31 inch (5-8mm) after assembled.
  6.  
  7. Install the radiator lower hose. Align the hose and position the clamp to prevent interference with engine components.
    NOTE
    When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses and clamps must be replaced.

  8.  
  9. Install automatic transmission cooler lines (if equipped),.
  10.  
  11. Install radiator fan assembly.
  12.  
  13. Connect the radiator fan motor electrical connector.
  14.  
  15. Install the radiator upper hose. Align the hose and position the clamp to prevent interference with the engine or the hood.
  16.  
  17. Connect negative cable to battery.
  18.  
  19. Fill cooling system with coolant.
  20.  
  21. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.
  22.  

 
label.common.footer.alt.autozoneLogo