2.4L MULTIAIR: Removal

1. Disconnect and isolate the negative battery cable.
2. Remove the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
3. If equipped, remove the front tow hook(s). Refer to HOOK(S), TOW, FRONT, REMOVAL AND INSTALLATION .
4. Recover the A/C refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
5. Drain the cooling system. Refer to STANDARD PROCEDURE .

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6. Remove the nut (1a) and the air cleaner inlet tube (1b).

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7. Remove the bolts (1a) and the nuts (1b) and the front bumper reinforcement (1c).

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8. Remove the bolts (1a) and disengage the retainers side (1b) and remove the radiator air deflector (1c).

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   NOTE:

   Plug and seal the ends of the transmission cooler and the transmission cooler lines to prevent leakage of oil, or moisture, contaminates, or impurities from entering into the system.

   NOTE:

   Clean any transmission fluid the may have leaked out during the removal process.

   NOTE:

   When removing the transmission oil cooler line on the 2.4L Multi Air engine, use Special Tool 8875A with the fingers of the tool facing the quick connect fitting.

9. Do not remove the retaining clips (1a), install Special Tool 8875A or equivalent over the quick connect fitting and disconnect the transmission oil cooler line (1b) from the transmission cooler (1c).

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10. Disengage the retainers (1a) and remove the transmission oil cooler (1b).

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11. Remove the bolt (1a) and the A/C line (1b) from the condenser.
12. Remove the bolt (2a) and the A/C line (2b) from the condenser.

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13. Remove the retaining clips (1a) and the A/C condenser (1b).

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14. Disconnect the cooling fan wire harness connector (1b) and the cooling fan resistor wire harness connector (1a). and detach the wire harness (1c).
15. Open the retaining clip (2b) and detach the lines.

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16. Remove the upper radiator hose (1).
17. Remove the lower radiator hose (2).

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    NOTE:

    Recover any coolant that may have spilled.

18. Remove the covers.
19. Remove the retaining brackets (2a) and the radiator/cooling fan assembly (2b).

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20. Disengage the retaining tabs (1a) and remove the cooling fan (1b).

INSTALLATION 

1. Inspect the radiator for damage.

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2. Install the cooling fan (1b) onto the radiator and engage retaining tabs (1a).

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3. Install the radiator/cooling fan assembly (2b) and the retaining brackets (2a).
4. Install the covers.

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5. Install the lower radiator hose (2).
6. Install the upper radiator hose (1).

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7. Attach the lines and close the retaining clips (2b).
8. Attach the wire harness (1c) and connect the cooling fan resistor wire harness connector (1a) and the cooling fan wire harness connector (1b).

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9. Install the A/C condenser (1b) and the retaining clips (1a).

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10. Using NEW  gasket seals, install the A/C line (2b) to the condenser and securely tighten the bolt (2a)
11. Using NEW  gasket seals, install the A/C line (1b) to the condenser and securely tighten the bolt (1a). Tighten the bolts (2) to the proper torque specifications. Refer to TECHNICAL SPECIFICATIONS .

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12. Install the transmission oil cooler (1b) and engage the retainers (1a).

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13. Remove the seal and plug from the transmission cooler and the transmission cooler lines.
14. Using NEW  gasket seals, position the transmission oil cooler lines (1b) connector, the retaining clips (1a) and snap in place on transmission cooler (1c). Make sure lines are securely connected.

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15. Install the radiator air deflector (1c) and engage the retainers side (1b) and securely tighten the bolts (1a).

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16. Install the front bumper reinforcement (1c). Tighten the bolts (1a) and the nuts (1b) to the proper torque specifications. Refer to TECHNICAL SPECIFICATIONS .

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17. Install the air cleaner inlet tube (1b) and securely tighten the nut (1a).
18. Fill the cooling system. Refer to STANDARD PROCEDURE .
19. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
20. If equipped, install the front tow hook(s). Refer to HOOK(S), TOW, FRONT, REMOVAL AND INSTALLATION or HOOK(S), TOW, REAR, REMOVAL AND INSTALLATION .
21. Install the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
22. Connect the negative battery cable.