Radiator Replacement

Radiator Replacement (L61)

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

1. Drain the coolant. Refer to Draining and Filling Cooling System (L61).
2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement.
3. Remove the right headlamp.




4. Loop a rope around each of the 2 tabs of the condenser and tie the rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.




6. Remove the upper radiator support brackets.
7. Reposition the radiator outlet hose clamp at the radiator using the J 38185.
8. Remove the radiator outlet hose from the radiator.





9. Reposition the radiator inlet hose clamp at the radiator using the J 38185.
10. Remove the radiator inlet hose from the radiator.








11. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
12. Remove the lower radiator air deflector retainers.
13. Remove the lower radiator air deflector.




14. Remove the right front fender liner.
15. Remove the right radiator air deflector retainers.
16. Remove the right radiator air deflector.




17. Remove the left radiator air deflector retainers.
18. Remove the left radiator air deflector.
19. Place a drain pan under the transmission oil cooler pipes.
20. Remove the transmission oil cooler pipes attachment nut from the transmission.
21. Remove the transmission oil cooler pipes from the transmission.








22. Remove the lower radiator support bracket bolts.
23. Remove the lower radiator support brackets.
24. Remove the radiator lower mounts.
25. Remove and discard the condenser mounting bolts.




26. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.




27. Remove and discard the condenser mounting nuts from the radiator.




28. Remove the radiator air side seals.




29. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
30. Remove the transmission oil cooler pipes from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement.
31. Pry upward on the fan shroud tabs at the radiator clips.




32. Remove the cooling fan and shroud assembly from the radiator.

Installation Procedure

1. Install the cooling fan and shroud assembly to the radiator.




2. Snap the fan shroud tabs into the radiator clips.
3. Install the transmission oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement.




4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.




5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.

Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

Important: Replace the condenser mounting bolts and nuts.




6. Install the condenser mounting nuts to the radiator.
7. Insert the condenser mounting tabs into the radiator clips.

Notice: Refer to Fastener Notice.

8. Install the condenser mounting bolts.




Tighten the bolts to 6 N.m (53 lb in).




9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.




10. The radiator air side seals must be in the proper position for proper air flow.

Important: Replace the radiator lower mounts as a pair or vibration may result.

11. Install the radiator lower mounts.




12. Install the lower radiator support brackets.
13. Install the lower radiator support bracket bolts.

Tighten the bolts to 60 N.m (44 lb ft).

14. Install the transmission oil cooler pipes to the transmission.




15. Install the transmission oil cooler pipes attachment nut to the transmission.

Tighten the nut to 7 N.m (62 lb in).





Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.




18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner.




21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Install the radiator inlet hose to the radiator.




25. Reposition the radiator inlet hose clamp at the radiator using the J 38185.
26. Install the radiator outlet hose to the radiator.




27. Reposition the radiator outlet hose clamp at the radiator using the J 38185.
28. Remove the rope attached to the condenser and upper tie bar.




29. Install the upper radiator support brackets.

Important: Do not allow the upper bracket to twist when tightening the screw or vibration may result.




30. Install the upper radiator support bracket bolts.

Tighten the bolts to 10 N.m (89 lb in).

31. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement.
32. Install the left headlamp.
33. Fill the coolant. Refer to Draining and Filling Cooling System (L61).
34. Inspect the transmission fluid level. Refer to Transmission Fluid Checking.