How to Replace a Radiator in a Plymouth Voyager

Written by ehow cars editor
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The radiator in your Plymouth Voyager keeps the engine from overheating. Running your Voyager with a damaged or leaky radiator can eventually cause expensive engine damage. Here's how to replace the radiator in a 1996 to 2000 model Plymouth Voyager.

Skill level:
Moderately Challenging

Things you need

  • Resealable container
  • Replacement radiator
  • Antifreeze
  • Distilled water

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  1. 1

    Disconnect the negative battery cable before you proceed. Open the radiator drain plug and drain the coolant into a resealable container. Remove the air intake resonator from the air cleaner. Remove the overflow tank filler hose on the coolant recovery system and disconnect the fan electrical connector, which can be found on the cooling fan module.

  2. 2

    Remove the mounting screw from the crossmember on the coolant recovery system overflow tank and the upper radiator crossmember mounting screws.

  3. 3

    Unhook the wiring connector on the engine block heater, if applicable, and take off the crossmember on the upper radiator. Remove the entire air cleaner and disconnect the transaxle cooler line. Plug the ends. Disconnect the radiator hoses from the radiator, and remove the radiator hose clips from the cooling fan.

  4. 4

    Remove the air conditioner condenser brackets divide it from the radiator. Detach the grill extension and lift the radiator carefully from the car. Be careful not to damage the fins when you lift it out.

  5. 5

    Install the new radiator, being sure that the air seals are positioned properly. Lower the radiator into position.

  6. 6

    Reinstall the engine components in the order they were removed, fastening all nuts and bolts securely. Reconnect the negative battery cable.

  7. 7

    Fill the system with a mixture of half antifreeze and half distilled water. Start the engine and let it warm up, then check the level and top it off, if necessary.

Tips and warnings

  • Recycle used engine coolant if it isn't old or contaminated. However, if you choose not to reuse it, take it to a garage or a hazardous waste facility for proper disposal.
  • Be sure to keep antifreeze in a sealed container out of the reach of children and pets, and if any is spilled, clean it up immediately. Remember that cats and dogs are attracted to antifreeze, which can be fatal if ingested.
  • To avoid scalds, wear gloves and protective clothing, and always be sure the engine is completely cool before replacing the radiator. The steam and hot liquid can cause serious burns.

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