Radiator Replacement

Radiator Replacement

Tools Required

* J 39400-A Halogen Leak Detector
* J 38185 Hose Clamp Pliers

Removal Procedure

1. Recover the refrigerant from the A/C system.
2. Drain the cooling system.
3. Remove the condenser.
4. Disengage tension on the radiator inlet hose clamp at the radiator using J 38185.
5. Disconnect the radiator inlet hose from the radiator.
6. Disengage tension on the radiator inlet hose clamp at the engine using J 38185.




7. Disconnect the radiator inlet hose from the engine.
8. Remove the radiator inlet hose.

Important: Lift up on the cooling fan and shroud assembly to disengage the tabs from the radiator slots.

9. Disconnect the cooling fan and shroud assembly from the radiator.




10. Disengage tension and reposition the surge tank inlet hose clamp at the radiator using J 38185.
11. Disconnect the surge tank inlet hose from the radiator.
12. Disconnect the upper transmission oil cooler line from the radiator.
13. Raise and support the vehicle.




14. Disengage tension on the radiator outlet hose clamp at the radiator using the J 38185.
15. Disconnect the radiator outlet hose from the radiator.
16. Disconnect the lower transmission oil cooler line from the radiator.




17. Disengage the generator cooling hose clamp at the radiator.
18. Disconnect the generator cooling hose (1) from the radiator.
19. Lower the vehicle.
20. Remove the radiator from the vehicle.

Installation Procedure

1. Install the radiator to the vehicle.
2. Raise the vehicle.
3. Connect the generator cooling hose (1) to the radiator.




4. Engage the generator cooling hose clamp at the radiator.
5. Connect the lower transmission oil cooler line to the radiator.
6. Connect the radiator outlet hose to the radiator.




7. Engage tension on the radiator outlet hose clamp at the radiator.
8. Lower the vehicle.
9. Connect the upper transmission oil cooler line to the radiator.
10. Connect the surge tank inlet hose to the radiator.




11. Engage tension on the surge tank inlet hose clamp at the radiator.

Important: Lift up on the cooling fan and shroud assembly and engage the tabs to the radiator slots.

12. Connect the cooling fan and shroud assembly to the radiator.
13. Install the radiator inlet hose.




14. Connect the radiator inlet hose to the engine.
15. Engage tension on the radiator inlet hose clamp at the engine using J 38185.
16. Connect the radiator inlet hose to the radiator.
17. Engage tension on the radiator inlet hose clamp at the radiator using J 38185.
18. Install the condenser.
19. Fill the cooling system.
20. Evacuate and recharge the A/C system.
21. Leak test the fittings of the component using J 39400-A.
22. Inspect the transmission fluid level.