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. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
3. Remove the condenser. Refer to Air Conditioning Condenser Replacement (Service and Repair).
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. Refer to Transmission Fluid Cooler Upper Pipe Assembly Replacement (Service and Repair).
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




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. Refer to Transmission Fluid Cooler Lower Pipe Assembly Replacement - Transmission to Auxiliary Cooler (Service and Repair).




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. Refer to Transmission Fluid Cooler Lower Pipe Assembly Replacement - Transmission to Auxiliary Cooler (Service and Repair).
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. Refer to Transmission Fluid Cooler Upper Pipe Assembly Replacement (Service and Repair).
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. Refer to Air Conditioning Condenser Replacement (Service and Repair).
19. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
21. Leak test the fittings of the component using J 39400-A .
22. Inspect the transmission fluid level. Refer to Transmission Fluid Check (Transmission Fluid Check).