Radiator: Service and Repair

Radiator Replacement (Gas)

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.

1. Remove the air cleaner assembly.
2. Remove the coolant recovery reservoir.

3. Remove the clamp at the radiator inlet using the J 38185.
4. Remove the radiator inlet hose (5) from the radiator.
5. Remove the outlet heater hose clamp at the radiator using the J 38185.
6. Remove the outlet heater hose (2) from the radiator.
7. Remove the automatic transmission cooler lines.
8. Remove the engine oil cooler lines.

9. Remove the fan shroud bolts (1) from the top of the radiator support.
10. Remove the fan shroud bolts (3) from the sides of the fan shroud.

11. Remove the radiator (2).
12. Remove the radiator insulators (1, 3).
13. Inspect the following components:
^ The radiator
^ The insulators
^ The hoses and clamps
^ The mounting hardware
Replace the components as necessary.

Installation Procedure

1. Install the radiator insulators (1, 3).
2. Install the radiator (2).

Notice: Refer to Fastener Notice.

3. Install the fan shroud bolts (1) to the top of the radiator support.

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

4. Install the fan shroud bolts (3) to the sides of the fan shroud.

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

5. Install the engine oil cooler lines.
6. Install the automatic transmission oil cooler lines.

7. Install the radiator inlet hose (5) to the radiator.
8. Install the hose clamp at the radiator inlet housing using the J 38185.
9. Install the outlet heater hose (2).
10. Install the outlet heater hose clamp using the J 39529.
11. Install the coolant recovery reservoir.
12. Install the air cleaner assembly.
13. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities.
14. Inspect the engine oil level. Refer to Approximate Fluid Capacities.