Radiator: Service and Repair

Radiator Replacement

^ 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 coolant recovery reservoir.
2. Remove the clamp at the radiator inlet using the J 38185.





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





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





12. Remove the radiator (2).
13. Remove the radiator insulators (1, 3).
14. 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 in Service Precautions.

3. Install the fan shroud bolts (1) to the top of the radiator support.
^ Tighten the bolts to 6 Nm (53 inch lbs.).
4. Install the fan shroud bolts (3) to the sides of the fan shroud.
^ Tighten the bolts to 6 Nm (53 inch lbs.).
5. Install the engine oil cooler lines.
6. Install the automatic transmission oil cooler lines.





7. Install the radiator outlet hose (4) to the radiator.
8. Install the radiator outlet clamp to the radiator outlet using the J 38185.
9. Install the radiator inlet hose (5) to the radiator.
10. Install the hose clamp at the radiator inlet housing using the J 38185.
11. Install the outlet heater hose (2).
12. Install the outlet heater hose clamp using the J 39529.
13. Install the coolant recovery reservoir.
14. Inspect the automatic transmission fluid level.
15. Inspect the engine oil level.