Radiator Replacement

Radiator Replacement

Tools Required

AU-525 Quick Connect Release Tool


Removal Procedure

Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
Caution: Refer to Radiator Cap Removal Caution (Service Precautions) .
2. Ensure engine is below 50 C before removing the coolant pressure cap.
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Service and Repair) .
4. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair) for 3.6L Engine or Engine Cover Replacement (Service and Repair) for 6.0L Engine.
5. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .
6. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair) for 3.6L Engine or Air Cleaner Inlet Duct Replacement (Service and Repair) for 6.0L Engine.
7. Remove the mass air flow meter. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement (Service and Repair) for 3.6L Engine or Mass Airflow Sensor with Intake Air Temperature Sensor Replacement (Service and Repair) for 6.0L Engine.
8. Detach the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (3.6L Engine) (Service and Repair)Radiator Inlet Hose Replacement (6.0L Engine) (Service and Repair) .
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
10. Remove the air deflector. Refer to Front Air Deflector Replacement (Service and Repair) .
11. Detach the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (3.6L Engine) (Service and Repair)Radiator Outlet Hose Replacement (6.0L Engine) (Service and Repair) .
12. Lower the vehicle.
13. Detach the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement (Service and Repair) .
14. Remove the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement (3.6L) (Service and Repair)Engine Coolant Air Bleed Hose Replacement (6.0L) (Service and Repair) .
15. Place a suitable container beneath the radiator and engine.




Non Registered Caution: Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 120919 .
Caution: When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.
16. Disconnect the transmission cooler line (2) from the flexible hose (1) using the AU-525 .

* Detach plastic cover from hose fitting and slide along pipe
* Open the AU-525 then close and clip around the hose to be disconnected.
* While holding the flexible hose (1) push the hose inwards with one hand, then pull back to separate from the steel hose piping (2).
* Repeat procedure for the second fitting.





17. Remove the radiator support brackets (2) from top of radiator by rasing the securing lock (3) 10mm and then sliding the bracket off the radiator slide pin (1). Carry out same procedure for other bracket.




18. Disconnect the cooling fans electrical connector (2) from the main wiring loom connector (1).




19. Remove the two radiator and condenser retaining bolts (1).





Important: When manoeuvring the condenser take care not to fracture the A/C lines.


20. Detach the condenser by lifting it out of the retaining brackets located on the radiator assembly.




21. Remove the radiator and fan assembly, by tilting it forward and lifting it out of the rubber grommets located in the cross member.



Installation Procedure





1. Install the radiator into the rubber retaining grommets located in the cross member.




2. Install the condenser into the radiator

Notice: Refer to Fastener Notice (Fastener Notice) .

3. Install the two radiator and condenser retaining bolts (1).

Tighten the radiator and condenser bolts to 11 N.m (97 lb in).





4. Install the radiator retaining brackets (2), onto the radiator slide pin (1).
5. Secure the retaining brackets by pushing the securing lock (3) downwards until lock reaches bottom of radiator bracket.




6. Connect the cooling fans electrical connector (2) to the main wiring loom connector (1)




Non Registered Caution: Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 120919 .
Caution: Ensure cloth is removed before carrying out installation procedure.
7. Connect the flexible hoses (1) to the transmission cooler lines (2), listen for an audible click to confirm fitting.
8. Push plastic cover forward along pipe and clip onto hose fitting.
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
10. Install the outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement (3.6L Engine) (Service and Repair)Radiator Outlet Hose Replacement (6.0L Engine) (Service and Repair) .
11. Lower vehicle.
12. Install the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement (3.6L) (Service and Repair)Engine Coolant Air Bleed Hose Replacement (6.0L) (Service and Repair) .
13. Install the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement (Service and Repair) .
14. Install the inlet hose. Refer to Radiator Inlet Hose Replacement (3.6L Engine) (Service and Repair)Radiator Inlet Hose Replacement (6.0L Engine) (Service and Repair) .
15. Install the air deflector. Refer to Front Air Deflector Replacement (Service and Repair) .
16. Install the mass air flow meter. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement (Service and Repair) for 3.6L Engine or Mass Airflow Sensor with Intake Air Temperature Sensor Replacement (Service and Repair) for 6.0L Engine.
17. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair) for 3.6L Engine or Air Cleaner Inlet Duct Replacement (Service and Repair) for 6.0L Engine.
18. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .
19. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair) for 3.6L Engine or Engine Cover Replacement (Service and Repair) for 6.0L Engine.
20. Install the battery ground lead to the vehicle. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
21. Fill the cooling system. Refer to Cooling System Draining and Filling (Service and Repair) .
22. Inspect cooling system for leaks.