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2.2 Diesel

  1. Disconnect the negative battery cable.
  2. Remove the front grill, refer to BODY article for more information.
  3. Remove the hood seal, refer to BODY article for more information.
  4. Remove the upper radiator crossmember.
  5. Remove ambient temperature sensor.
  6. Raise vehicle and support.
  7. Drain radiator, refer to COOLING SYSTEM MECHANICAL article for more information.
  8. Disconnect the electrical connector for the radiator fan.
  9. Remove the underbody plate (skid plate), refer to BODY article for more information.
  10. Remove the lower radiator hose.
  11. Remove the 2 lower bolts for the inner cooler mounting to radiator.
  12. Lower vehicle.
  13. Remove the upper radiator hose.
  14. Remove the 4 upper bolts for the inner cooler mounting to radiator.
  15. Remove inner cooler from radiator by lifting the inner cooler up off of the 2 lower mounting tabs and push it toward the front of vehicle. These tabs are on the bottom of the inner cooler and lock into the bottom of the radiator.
    Fig 1: Identifying Mounting Tabs
    G01857997Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the radiator from vehicle.
    Fig 2: Locating Starter
    G01857998Courtesy of DAIMLERCHRYSLER CORP.
  17. Disconnect the electrical connectors from the starter.
    Fig 3: Identifying Electrical Connections
    G01857999Courtesy of DAIMLERCHRYSLER CORP.
  18. Disconnect the battery cable from the starter.
  19. Remove the lower mounting bolt and ground cable.
  20. Remove the upper mounting bolt.
  21. Remove starter.
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