How to Replace a Radiator on a 1997 Dodge Intrepid
- 1). Place the drain pan under the radiator petcock. Loosen the petcock and allow the antifreeze to drain into the drain pan. If the drain pan is clean, the antifreeze is less than five years old, and you know that the antifreeze is the MOPAR antifreeze, you can reuse the antifreeze mixture. Otherwise, discard the mixture.
- 2). Remove the coolant reservoir cap. Open the thermostat bleed valve. Remove the cylinder block drain plugs, which are located behind each exhaust manifold. Unbolt and remove the radiator's upper crossmember using the appropriate socket. Loosen the hose clamps using the screwdriver, pliers or socket, whichever is appropriate. This depends on the type of clamps used on the hoses. Remove the hoses.
- 3). Disconnect the transmission lines from the cooler using the appropriate line wrench. Plug the lines with a bolt or a rag to prevent transmission fluid from leaking out. Disconnect the wiring harness connector for the fan from the EFI module, located near the radiator.
- 4). Remove the mounting screws from the upper radiator. Disconnect the engine block heater wire, if your model is equipped with one. Remove the screws that attach the air conditioning condenser to the radiator. These are located at the front of the radiator. Lean the condenser against the bumper. Lift the radiator and cooling fan assembly from the Intrepid. Remove the fan from the radiator. If the fan is held on with plastic wire ties, simply cut the ties.
- 5). Attach the fan to the new radiator using new ties, if ties are used to hold it on, otherwise bolt the fan assembly to the radiator using a socket. Side the radiator and the fan assembly into position, positioning it on the lower rubber isolator in the mount holes.
- 6). Push the air conditioning condenser forward and reattach it to the radiator. Tighten the screws to 45 inch-pounds of torque. Install the radiator mounting bolts and tighten them to 123 inch-pounds of torque. Reconnect the engine block heater wire.
- 7). Reinstall the lower radiator hose, the transmission cooler lines, the upper radiator hose and the radiator crossmember. Reinstall the block drain plugs. Plug the electrical connector back in. Reconnect the negative battery cable. Make sure the petcock on the new radiator is closed. Fill the radiator with antifreeze and water until it is about three-quarters full. Open the thermostat bleed valve. Attach a 1/4-inch diameter hose to the bleed valve. Run the other end into a clean container. Fill the radiator the rest of the way, until you see a steady stream of coolant flow out of the bleed valve.
- 8). Squeeze the upper radiator hose until all the air is removed from the system. Close the bleed valve, then fill the radiator coolant reservoir to the proper level. Reinstall the reservoir cap. Remove the hose from the bleed valve. Close the bleed valve.
- 9). Start the engine. Allow it to run until it gets to normal operating temperature. Check the cooling system and transmission cooler lines for leaks. Check the radiator antifreeze level and the transmission fluid level. Top off each as needed.
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