Radiator: Service and Repair

REMOVAL

WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

1. Disconnect negative battery cable from battery.
2. Drain cooling system.
3. Remove engine air inlet duct.
4. Remove upper radiator hose from the radiator.
5. Disconnect and cap automatic transmission hoses, if equipped.

Figure 23:

6. Remove radiator to battery strut and ground strap.
7. For vehicles equipped with dual fans, remove the battery and battery tray.
8. Remove fan module assembly by disconnecting fan motor electrical connector.

Figure 24:

9. Remove fan shroud retaining screws, located on the top of the shroud. Lift shroud up and out of bottom shroud attachment clips separating shroud from radiator. For dual fan applications, the left fan module may be removed first, then the right side module last. Fan damage should always be avoided.
10. Remove the lower radiator hose.
11. Remove upper radiator isolator bracket mounting screws. Disconnect the engine block heater wire, if equipped.

Figure 25:

12. Remove the air conditioning condenser attaching screws located at the front of the radiator, if equipped, then lean condenser forward.

NOTE: It is not necessary to discharge the air conditioning system to remove the radiator.

13. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fine or water tubes during removal.


INSTALLATION
1. Slide radiator down into position behind radiator support (yoke).
2. Attach air conditioning condenser to radiator, if equipped, with four mounting screws. Tighten screws to 5.4 Nm (50 inch lbs.). Then seat the radiator assembly lower rubber isolators into the mounting holes provided in the lower crossmember.
3. Tighten radiator isolator mounting bracket screws to 10 Nm (90 inch lbs.). The radiator should have clearance to move up, approximately 5-8 mm (0.20-0.31 inch) after assembled.
4. Install lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
5. Connect automatic transmission hoses, if equipped. Tighten hose clamps to 4 Nm (35 inch lbs.).
6. Slide fan module down into clip(s) on lower radiator flange. For dual fan application, install the right fan module first and then the left fan module. Install retaining screws and tighten to 7.5 Nm (65 inch lbs.).
7. Connect the cooling fan motor electrical connector(s).
8. Install upper radiator hose. Align the hose and position the clamp so they will not interfere with the engine or the hood.
9. For vehicles equipped with dual fans; install the battery tray and battery.
10. Connect negative cable to battery.
11. Fill cooling system with coolant.
12. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.