PT Cruiser Radiator Removal

Chryslers PT Cruiser uses a one-row, plastic finned radiator designed to prevent premature corrosion. Older radiators used metal fins, through which the radiator fluid passed through and was cooled. The disadvantage to these radiators was that the metal fins were prone to corrosion, and the radiator had to be cleaned, or rotted out. The PT Cruisers plastic fins do not corrode, but can become clogged. When this occurs, the radiator must be replaced, since a traditional cleaning would melt the plastic fins. Replacement begins with removal.

Before draining the radiator, allow the engine time to cool, as hot radiator fluid will be pressurized within the radiator and the fluid can easily burn skin. Unlike most radiators, where the radiator cap is located on top of the radiator, the PT Cruisers radiator cap is mounted on top of the engine. Trace the upper radiator hose to the engine to locate the cap. Remove the radiator cap, then place a catch pan underneath the radiator. At the base of the radiator, on the drivers side, is a single plastic drain bolt. Remove this bolt with a wrench and allow the fluid to drain into the catch pan. Although not necessary, it is a good idea to reinstall the drain plug into the radiator to avoid losing it.

The radiator has two large hoses, one at the top of the radiator and one at the bottom. Each hose is secured to the radiator, and to the engine, with a hose clamp. Because the radiator and not the engine will be removed, it is not necessary to disconnect the two hoses from the engine. The upper radiator hose is the easier of the two hoses to remove since it is easily accessible. The lower radiator hose must be accessed from underneath the vehicle. For safety purposes, raise the vehicle with a floor jack and lower it onto jack stands before climbing underneath the car. Each hose is secured to the radiator with a hose clamp. Once the clamp is loosened with a screwdriver, pull each hose off the radiator.

The fan assembly consists of the fan blades, the fans electrical motor and the fan shroud. These three components are all part of a single assembly, meaning that the components are not removed separately. Because the fan assembly is held in place against the radiator, the fan motor should be disconnected first to avoid any damage to the wiring from the weight of the radiator once it is removed. The motor is located at the center of the fan blades. The wiring that powers the motor exits from the drivers side of the motor. Trace the wiring starting at the motor until a plastic electrical connection is reached. Pinch the two sides of the connection and pull the two connection pieces apart to disconnect the motor.

The fan assembly itself attaches to the radiator with six bolts. Two bolts are located at the top of the assembly, one bolt is located on each side and the remaining two bolts are located at the bottom of the assembly. With the bolts removed, the fan assembly can be pulled away from the radiator and out of the engine compartment.

With the fan assembly and the radiator hoses out of the way, the two transmission cooler lines located at the bottom of the radiator can be removed. Note that once the lines are removed, a small amount of transmission fluid will likely drip out of the lines and out of the radiator, so the catch pan should be placed underneath the lines. The lines attach to the radiator with an integral nut. These lines are easily bent and expensive to replace, and should not be disconnected with a standard wrench. Instead, use a flare-nut wrench. Finally, the radiator itself is held within the engine bay with 12 bolts, six on each side. Remove the bolts and pull the radiator out of the engine bay.