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Disconnect the negative battery terminal (deep 12mm socket)
01
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Remove the 3 plastic rivets from each fender well
02
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Remove the 10mm (use a deep socket) screw from each fender well
03
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Unhook the fog light wiring harness (one on each side)
04
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Remove the 3 plastic rivets at the lower fascia
05
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Remove the 4 large plastic rivets that attach the lower splash shield to the unibody
06
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Remove the 7 phillips screws attaching the fascia grille to the header panel
07
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OPTIONAL: Remove bumper bracket
08
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OPTIONAL: Install tow hooks in factory location
09
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Remove radiator petcock and radiator cap to drain radiator
10
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Remove the long headlamp retaining screw from each side (7mm)
11
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Remove headlamps by pulling firmly forward to dislodge the 3 ballstuds
12
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Remove the 8 torx bolts attaching the header panel to the frame/crossmember (T30)
13
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Remove the header panel mounting tabs (1 on each side)
14
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Remove the single rivet holding the air box inlet to the header panel (driver side)
15
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Disconnect the temperature sensor
16
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Disconnect the headlamp wiring harness
17
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OPTIONAL: Remove and replace the fan relay (2x8mm)
18
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Remove the upper crossmember bolts (4)
19
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Remove 2x13mm hood latch bolts
20
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Remove the upper cross member
21
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Remove the upper radiator hose
22
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Remove the air box inlet duct
23
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Remove the 3/8 rubber transmission hoses that run to the transmission oil cooler
24
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Remove the radiator mounting bolts (2x10mm)
25
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Remove A/C lines from condenser (2x13mm)
26
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Disconnect the electric fan wiring harness (passenger side)
27
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Lift up on the radiator/fan/shroud/condenser/aux cooler assembly and remove it
28
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New fan belt
29
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Rotate the belt tensioner to the right
30
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Belt routing diagram
31
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Remove the fan shroud and e-fan from the old radiator
32
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Place the shroud and fan on the new radiator and HAND TIGHTEN the 4 shroud bolts
33
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Remove the auxiliary cooler and condenser from old radiator
34
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My weeping radiator
35
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Remove the 2 plastic air diverters from old radiator and reuse
36
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Trans Cooler Hose Diagram
37
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New long trans cooler line
38
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Line is run between radiator and shroud
39
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New and Old Lower Transmission Cooler Line
40
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Remove the lower plastic air diverter from the old radiator and reuse
41
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Reinstall assembly, seat dowels in mount
42