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2.0L/2.4L Engine

Fig 1: Charge Air Cooler Locating Tab
GC0019365Courtesy of DAIMLERCHRYSLER CORP.
1 - LOCATING TAB
2 - LOWER RADIATOR SUPPORT CROSSMEMBER
3 - RADIATOR MOUNT BUSHING
4 - CHARGE AIR COOLER
  1. Non-Turbo Vehicles:  Install the lower air seal to radiator.
    NOTE: Turbocharger Equipped Vehicles: When lowering radiator, make sure lower radiator pins engage properly through charge air cooler locating tabs (1). See Fig 1.
  2. Position radiator into mounting position.
  3. Position A/C condenser against radiator. Hand start fasteners.
  4. Turbocharger Equipped Vehicles:  Install fasteners attaching charge air cooler to radiator. Torque fasteners to 8 N.m (70 in. lbs.).
    Fig 2: Radiator Air Seals
    GC0021852Courtesy of DAIMLERCHRYSLER CORP.
    1 - A/C CONDENSER
    2 - SIDE AIR SEALS
    3 - LOWER AIR SEAL
  5. Install radiator fan/shroud assembly. Hand start fasteners.
  6. Torque all condenser fasteners to 8 N.m (70 in. lbs.).
  7. Torque all radiator fan fasteners to 6 N.m (55 in. lbs.).
  8. Non-Turbo Vehicles with Automatic Transmission:  Install fasteners attaching transmission oil cooler to radiator. Torque fasteners to 8 N.m (70 in. lbs.).
  9. Raise vehicle on hoist.
    Fig 3: Identifying Cooling Module Assembly
    GC0021833Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR CLOSURE PANEL
    2 - COOLING MODULE
    3 - RADIATOR FAN CONNECTOR
    4 - LOWER RADIATOR CROSSMEMBER
  10. Non-Turbo Vehicles:  Connect the lower air seal to the side air seals.
  11. Connect lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
  12. Connect the radiator fan electrical connector.
  13. Turbocharger Equipped Vehicles:  Connect the power steering hoses.
  14. Close radiator draincock.
  15. Lower vehicle.
    Fig 4: Identifying Cooling Module Assembly
    GC0021833Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR CLOSURE PANEL
    2 - COOLING MODULE
    3 - RADIATOR FAN CONNECTOR
    4 - LOWER RADIATOR CROSSMEMBER
  16. Turbocharger equipped vehicles:  Inspect radiator inlet neck o-ring. Replace if necessary. Install radiator inlet neck. Torque fasteners to 6 N.m (55 in. lbs.).
  17. Connect upper radiator hose. Align the hose and position the clamp to prevent interference with the engine or hood.
  18. Install upper radiator closure panel and center brace, (Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL - INSTALLATION) .
  19. Install grille, (Refer to BODY/EXTERIOR/GRILLE - INSTALLATION) .
  20. Install battery tray and battery.
  21. Connect positive battery cable. Connect negative battery cable.
  22. Install air cleaner housing assembly.
  23. Fill cooling system with coolant, (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
  24. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.
  25. Turbocharger Equipped Vehicles:  Check power steering fluid level. Fill as needed.
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