Condenser, Fan, and Radiator Assembly Removal and Installation
Single Use Fasteners and Components
  • Air Conditioning Compressor and Condenser Hose Seal
  • Air Conditioning Evaporator Inlet Tube Seal

Removal Procedure

  1. Drain the drive motor battery cooling system. Drive Motor Battery Cooling System Draining and Filling
  2. Recover the refrigerant.Refrigerant Recovery and Recharging

    3. Object ID: 5875805
  3. Hood Front Bumper Bracket Bolt(1)»Remove[3x]
  4. Hood Front Bumper Bracket Support(2)»Remove

    5. Object ID: 5901655

    Note: Some components not shown for graphic clarity.

  5. Remove the crossbody front wiring harness retainer (2).

    6. Object ID: 5901657

    Note: Some components not shown for graphic clarity.

  6. Fuse Block Nut(1)»Remove[2x]
  7. Retainer(2)»Disengage
  8. Engine Wiring Harness Fuse Block Bracket- Upper(3)@Engine Wiring Harness Fuse Block Bracket- Lower(4)»Reposition

    9. Object ID: 6371827
  9. Engine Wiring Harness Fuse Block Bracket Bolt(1)»Remove[3x]
  10. Engine Wiring Harness Fuse Block Bracket(2)»Remove
  11. Electrical Connector@Airbag Front End Discriminating Sensor»Disconnect[2x]

    12. Object ID: 5876866
  12. Radiator Surge Tank Bracket Bolt(1)»Remove[2x]

    13. Note: The drive motor battery radiator surge tank will be repositioned with the bracket.

  13. Radiator Surge Tank Bracket(2)»Reposition

    14. Object ID: 5898221
  14. Drive Motor Battery Control Module Bracket Nut(1)»Remove[4x]
  15. Hybrid/Electric Vehicle Propulsion System Coolant Control Valve 1- Left Side(2)»Reposition
  16. Hybrid/Electric Vehicle Propulsion System Coolant Control Valve 1- Right Side(3)»Reposition

    17. Object ID: 5876869
  17. Disconnect the electrical connector and release the wiring harness retainers as necessary.
  18. Radiator Support Bolt(1)»Remove[4x]
  19. Radiator Upper Support(2)»Remove

    20. Object ID: 5830323
  20. Radiator Air Upper Baffle Retainer(1)»Remove[5x]
  21. Radiator Air Upper Baffle(2)»Remove

    22. Object ID: 5830454
  22. Radiator Air Side Baffle Retainer(1)»Remove[3x]

    23. Object ID: 5830462

    Note: Some components not shown for graphic clarity

  23. Radiator Air Side Baffle - Right Side(1)»Remove

    24. Object ID: 5830442
  24. Radiator Air Side Baffle Retainer(1)»Remove[3x]

    25. Object ID: 5830448

    Note: Some components not shown for graphic clarity

  25. Radiator Air Side Baffle - Left Side(1)»Remove

    26. Object ID: 5841657

    Note: Some components not shown for graphic clarity

  26. Depress the retainers (1) on each side of the drive motor battery surge tank inlet hose (2) and remove the hose from the radiator.

    27. Object ID: 5921486
  27. Air Conditioning Compressor and Condenser Hose Nut(1)»Remove
  28. Air Conditioning Compressor and Condenser Hose(2)@Air Conditioning Condenser»Remove
  29. Air Conditioning Compressor and Condenser Hose Seal(3)»Remove and DISCARD

    30. Object ID: 5902742

    Note: Some components not shown for graphic clarity

  30. Retainer(1)»Release
  31. Drive Motor Control Module Radiator Outlet Hose(2)@Radiator»Remove
  32. Radiator Inlet Hose Clip(3)@Cooling Fan Motor»Remove

    33. Object ID: 5844043
  33. Retainer(1)»Release
  34. Drive Motor Control Module Radiator Inlet Hose(2)@Radiator»Remove

    35. Object ID: 5845857
  35. Air Conditioning Condenser Tube Nut(1)»Remove
  36. Air Conditioning Condenser and Evaporator Hose(2)»Remove
  37. Air Conditioning Evaporator Inlet Tube Seal(3)»Remove and DISCARD

    38. Object ID: 5835489

    Note: Some components not shown for graphic clarity

  38. Electrical Connector(1)@Cooling Fan Motor»Disconnect
  39. Radiator Inlet Hose Clip(2)@Cooling Fan Motor»Remove

    40. Object ID: 5832362
  40. Lift the radiator, air conditioning condenser, and the cooling fan as an assembly (1) out of the mounts and lower it from the vehicle.

Installation Procedure


    Object ID: 5832362
  1. Raise the radiator, air conditioning condenser, and the cooling fan assembly (1) from the bottom and install into the mounts.

    2. Object ID: 5835489

    Note: Some components not shown for graphic clarity

  2. Radiator Inlet Hose Clip(2)@Cooling Fan Motor»Install
  3. Electrical Connector(1)@Cooling Fan Motor»Connect

    4. Object ID: 5844043
  4. Drive Motor Control Module Radiator Inlet Hose(2)@Radiator»Install
  5. Retainer(1)»Engage

    6. Object ID: 5845857

    Caution: Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution.

  6. Air Conditioning Evaporator Inlet Tube Seal(3)»Install NEW
  7. Air Conditioning Condenser and Evaporator Hose(2)»Install

    8. Caution: Refer to Fastener Caution.

  8. Air Conditioning Condenser Tube Nut(1)»Install and tighten—Fastener Specifications

    9. Object ID: 5902742

    Note: Some components not shown for graphic clarity

  9. Radiator Inlet Hose Clip(3)@Cooling Fan Motor»Install
  10. Drive Motor Control Module Radiator Outlet Hose(2)@Radiator»Install
  11. Retainer(1)»Engage

    12. Object ID: 5841657

    Note:

    • Some components not shown for graphic clarity
    • Ensure that the drive motor battery surge tank inlet hose (2) is fully seated to the radiator

  12. Install the drive motor battery surge tank inlet hose (2) to the radiator.

    13. Object ID: 5921486
  13. Air Conditioning Compressor and Condenser Hose Seal(3)»Install NEW
  14. Air Conditioning Compressor and Condenser Hose(2)@Air Conditioning Condenser»Install
  15. Air Conditioning Compressor and Condenser Hose Nut(1)»Install and tighten—Fastener Specifications

    16. Object ID: 5830448

    Note: Some components not shown for graphic clarity

  16. Radiator Air Side Baffle - Left Side(1)»Install

    17. Object ID: 5830442
  17. Radiator Air Side Baffle Retainer(1)»Install[3x]

    18. Object ID: 5830462

    Note: Some components not shown for graphic clarity

  18. Radiator Air Side Baffle - Right Side(1)»Install

    19. Object ID: 5830454
  19. Radiator Air Side Baffle Retainer(1)»Install[3x]

    20. Object ID: 5830323
  20. Radiator Air Upper Baffle(2)»Install
  21. Radiator Air Upper Baffle Retainer(1)»Install[5x]

    22. Object ID: 5876869
  22. Radiator Upper Support(2)»Install
  23. Radiator Support Bolt(1)»Install and tighten[4x]—Fastener Specifications
  24. Connect the electrical connector and install the wiring harness retainers as necessary.
  25. Electrical Connector@Airbag Front End Discriminating Sensor»Connect[2x]

    26. Object ID: 5898221
  26. Hybrid/Electric Vehicle Propulsion System Coolant Control Valve 1- Right Side(3)»Install
  27. Hybrid/Electric Vehicle Propulsion System Coolant Control Valve 1- Left Side(2)»Install
  28. Drive Motor Battery Control Module Bracket Nut(1)»Install and tighten[4x]—Fastener Specifications

    29. Object ID: 5876866
  29. Radiator Surge Tank Bracket(2)»Install
  30. Radiator Surge Tank Bracket Bolt(1)»Install and tighten[2x]—Fastener Specifications

    31. Object ID: 6371827
  31. Engine Wiring Harness Fuse Block Bracket(2)»Install
  32. Engine Wiring Harness Fuse Block Bracket Bolt(1)»Install and tighten[3x]—Fastener Specifications

    33. Object ID: 5901657
  33. Engine Wiring Harness Fuse Block Bracket- Upper(3)@Engine Wiring Harness Fuse Block Bracket- Lower(4)»Install
  34. Retainer(2)»Engage
  35. Fuse Block Nut(1)»Install and tighten[2x]—Fastener Specifications

    36. Object ID: 5901655
  36. Install the crossbody front wiring harness retainer (2).

    37. Object ID: 5875805
  37. Hood Front Bumper Bracket Support(2)»Install
  38. Hood Front Bumper Bracket Bolt(1)»Install and tighten[3x]—Fastener Specifications
  39. Recharge the refrigerant.Refrigerant Recovery and Recharging
  40. Inspect for refrigerant leaks.
  41. Fill the drive motor battery cooling system to the proper level. Drive Motor Battery Cooling System Draining and Filling
  42. Inspect for coolant leaks.