2002 Dodge Neon Remove and Install Radiator

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The buildup of rust and mineral deposits inside a radiator can severely restrict the unit's operation in your 2002 Dodge Neon. If you overlook the problem, you may soon end up with an overheated engine and costly shop repairs. Prevent unnecessary engine damage and expensive repairs by removing your old radiator and installing a new unit in your Neon. A radiator in good condition will not only save your engine, but also extend its service life down the road. This procedure applies to non-turbo models only.

[edit] Tools Used

Tools
Wrench
Large drain pan
Slip-joint pliers
Ratchet
Socket set
2 plastic sheets
2 rubber bands
Floor jack
2 safety stands
Small funnel

[edit] Remove and Install Radiator

Removing the Radiator

  • Detach the ground (black) battery cable wrench.
  • Put a large drain pan under the radiator and open the drain plug. Drain all the coolant, cover the drain pan and move it to the side.
  • Remove the upper radiator hose clamp at the radiator with a pair of slip-joint pliers. Pull the hose off the radiator.
  • Unplug the cooling fan and unfasten the fan assembly with a ratchet and socket. Remove the fan from the vehicle.
  • Unfasten the clamps holding the oil cooler lines to the radiator fittings with a ratchet and socket and then pull the hoses off the radiator. Cover the hoses with a plastic sheet and rubber band to keep dirt off the system.
  • Raise the front of your Neon with a floor jack and support it on safety stands (if you need better access to the lower radiator hose).
  • Remove the lower radiator hose clamp at the radiator with a pair of slip-joint pliers. Pull the hose off the radiator.
  • Unfasten the radiator upper isolator bracket with a ratchet and socket.
  • Unbolt the condenser in front of the radiator with a ratchet and socket and lean the condenser away from the radiator. Do not disconnect the lines from the condenser.
  • Take the radiator out of the engine compartment.

Installing the Radiator

  • Position the radiator in place in the engine compartment.
  • Fasten the condenser with a ratchet and socket.
  • Fasten the radiator upper isolator bracket with the ratchet and socket.
  • Connect the lower radiator hose to the radiator and secure it with the clamp using the slip-joint pliers.
  • Lower the front of your Neon off the safety stands with a floor jack.
  • Connect the oil cooler lines to the radiator fittings and tighten the clamps with the ratchet and socket.
  • Replace the cooling fan assembly and plug in the electrical connector.
  • Connect the upper radiator hose to the radiator and secure it with the clamp using the slip-joint pliers.
  • Refill the radiator with the coolant using a small funnel.
  • Attach the ground (black) battery cable with the wrench.

[edit] Tips & Warnings

  • Dodge recommends replacing the cooler lines once they have been disconnected, since the inner wall may become damaged when removed.
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