I want to replace the radiator without removing any of the ac componets. Can I do this without removing the front bumper?
Jan 23, 2019 at 6:34 AM
Radiator removal
2012 CHRYSLER 200
CHYRSLERMAN
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Good morning
When I have done this, I removed the radiator/condenser as an assembly. There is not enough room to remove just the radiator and leaving the condenser in the car.
The procedure is below.
REMOVAL
1. Disconnect negative cable from auxiliary jumper terminal.
2. Remove engine cover.
3. Remove air box assembly See: Air Cleaner Housing > Removal and Replacement > Air Cleaner Body - Removal.
4. Recover A/C system See: Heating and Air Conditioning > Procedures > Refrigerant System Recovery.
WARNING: Do not remove pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.
5. Drain cooling system See: Cooling System > Procedures.
6. Remove the front bumper facia See: Front Bumper Cover / Fascia > Removal and Replacement > Front Bumper Fascia - Removal.
7. Remove under belly pan.
8. Remove front bottom splash shield.
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imageOpen In New TabZoom/Print
9. Remove upper (2) and lower radiator hoses at radiator.
10. Disconnect radiator fan electrical connector (1).
imageOpen In New TabZoom/Print
imageOpen In New TabZoom/Print
11. Remove the cooling fan assembly See: Radiator Cooling Fan > Removal and Replacement > Cooling Fan - Removal.
12. Disconnect both A/C lines at condenser/cooler.
13. Remove transmission oil cooler tubes support bracket bolt at left side of radiator (2).
CAUTION: Plastic tanks, while stronger than brass are subject to damage by impact, such as wrenches.
14. Remove the two torx screws located on the upper radiator support that hold the upper radiator mounting brackets.
15. Tilt the top of the radiator rearward so the mounting brackets slide out of the upper core support.
16. Remove radiator/condenser assembly by lifting the assembly out of the vehicle between the engine and the core support.
17. Separate the A/C condenser from the radiator.
When I have done this, I removed the radiator/condenser as an assembly. There is not enough room to remove just the radiator and leaving the condenser in the car.
The procedure is below.
REMOVAL
1. Disconnect negative cable from auxiliary jumper terminal.
2. Remove engine cover.
3. Remove air box assembly See: Air Cleaner Housing > Removal and Replacement > Air Cleaner Body - Removal.
4. Recover A/C system See: Heating and Air Conditioning > Procedures > Refrigerant System Recovery.
WARNING: Do not remove pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.
5. Drain cooling system See: Cooling System > Procedures.
6. Remove the front bumper facia See: Front Bumper Cover / Fascia > Removal and Replacement > Front Bumper Fascia - Removal.
7. Remove under belly pan.
8. Remove front bottom splash shield.
imageOpen In New TabZoom/Print
imageOpen In New TabZoom/Print
9. Remove upper (2) and lower radiator hoses at radiator.
10. Disconnect radiator fan electrical connector (1).
imageOpen In New TabZoom/Print
imageOpen In New TabZoom/Print
11. Remove the cooling fan assembly See: Radiator Cooling Fan > Removal and Replacement > Cooling Fan - Removal.
12. Disconnect both A/C lines at condenser/cooler.
13. Remove transmission oil cooler tubes support bracket bolt at left side of radiator (2).
CAUTION: Plastic tanks, while stronger than brass are subject to damage by impact, such as wrenches.
14. Remove the two torx screws located on the upper radiator support that hold the upper radiator mounting brackets.
15. Tilt the top of the radiator rearward so the mounting brackets slide out of the upper core support.
16. Remove radiator/condenser assembly by lifting the assembly out of the vehicle between the engine and the core support.
17. Separate the A/C condenser from the radiator.
Image (Click to enlarge)
Jan 23, 2019 at 7:50 AM
The bumper cover has to come off to get the radiator out as there are bolts and fasteners that you need to get to from that side. The condenser is mounted to the radiator and cannot be separated without that same access. Can it be removed without recovering the A/C? Maybe, but I think you would need to remove the upper core support to get access to the bolts. For most shops it's easier to evacuate the A/C than fight with removing a lot of extra parts.
Jan 23, 2019 at 8:45 AM
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