Radiator Replacement (Heavy Duty Cooling)

Radiator Replacement (Heavy Duty Cooling)

Special Tools
* J 38185 Hose Clamp Pliers
* J 38778 Door Trim Pad Clip Remover

Removal Procedure

1. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill LSA) Service and RepairCooling System Draining and Filling (GE 47716 LSA) Service and RepairCooling System Draining and Filling (Static Fill LF1, LLT,LFW or LFX) Service and RepairCooling System Draining and Filling (GE 47716 LF1, LLT,LFW or LFX) Service and Repair.
2. Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LSA) Engine Coolant Fan Shroud Replacement (LF1, LLT,LFW or LFX) Service and Repair.
3. Disconnect transmission cooler lines at radiator.
4. Remove the front fascia. Refer to Front Bumper Fascia Replacement
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.




6. Remove the lower condenser mounting bolts.




7. Remove the upper condenser mounting bolts.
8. Disconnect transmission cooler lines at auxiliary transmission cooler.




9. Disconnect the lower retainer pins of the side air baffle from the radiator.
10. Lower the vehicle.
11. Remove the radiator support bracket bolts.
12. Remove the radiator support brackets.




13. Use J 38185 to disconnect the surge tank inlet hose from the radiator. Reposition the hose aside.




14. Using J 38185 disengage tension on the radiator inlet hose clamp and disconnect the hose from the radiator.
15. Using J 38185 disengage tension on the radiator outlet hose clamp and disconnect the hose from the radiator.
16. Disconnect the upper retainer pins on the side air baffle from the radiator.
17. Remove the radiator, with the auxiliary transmission cooler attached.




18. Remove the auxiliary transmission cooler to radiator mountaing bolts.
19. Remove the auxiliary transmission.

Installation Procedure

1. Install the auxiliary transmission.




2. Install the auxiliary transmission cooler to radiator mountaing bolts and tighten to 5 Nm (44 lb in).
3. Install the radiator, with the auxiliary transmission cooler attached.
4. Connect the upper retainer pins of the side air baffle to the radiator.
5. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.




6. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.




7. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the hose clamp to secure the hose.
8. Install the radiator/condenser upper support.
9. Install the radiator support brackets.

Caution: Refer to Fastener Caution Fastener Caution.

10. Install the radiator support bracket bolts and tighten to 9 Nm (80 lb in).
11. Raise and support the vehicle.




12. Connect the lower retainer pins of the side air baffle to the radiator.
13. Connect transmission cooler lines at auxiliary transmission cooler.




14. Install the upper condenser mounting bolts and tighten to 5.4 Nm (48 lb in).




15. Install the lower condenser mounting bolts and tighten to 5.4 Nm (48 lb in).
16. Lower the vehicle.
17. Install the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LSA) Engine Coolant Fan Shroud Replacement (LF1, LLT,LFW or LFX) Service and Repair.
18. Connect transmission cooler lines at radiator.
19. Install the front fascia. Refer to Front Bumper Fascia Replacement
20. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LSA) Service and RepairCooling System Draining and Filling (GE 47716 LSA) Service and RepairCooling System Draining and Filling (Static Fill LF1, LLT,LFW or LFX) Service and RepairCooling System Draining and Filling (GE 47716 LF1, LLT,LFW or LFX) Service and Repair.