Removal and Installation

REMOVAL

WARNING: Do not open the radiator draincock with the system hot and under pressure because serious burns from coolant can occur.

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

1. Drain cooling system, refer to Service and Repair

2. Remove radiator fan, refer to Service and Repair

3. TURBO VEHICLES: Disconnect and cap the power steering hoses.

4. Disconnect lower radiator hose.






5. NON-TURBO VEHICLES WITH AUTOMATIC TRANSMISSION: Remove two fasteners attaching transmission oil cooler to radiator.

6. NON-TURBO VEHICLES: Dislodge lower radiator air seal from side radiator air seals.






7. Remove fasteners attaching A/C condenser to radiator. Reposition A/C condenser.

8. TURBO VEHICLES: Remove fasteners attaching charge air cooler to radiator.






9. Remove radiator assembly by lifting it up from the engine compartment. Care should be taken not to damage the cooling fins and tubes during removal.






10. NON-TURBO VEHICLES: Remove the lower air seal from radiator.







INSTALLATION

1. NON-TURBO VEHICLES: Install the lower air seal to radiator.






NOTE: Turbocharger equipped vehicles-when lowering radiator, make sure lower radiator pins engage properly through charge air cooler locating tabs.






2. Position radiator into mounting position.

3. Position A/C condenser against radiator. Hand start fasteners.

4. TURBO VEHICLES: Install fasteners attaching charge air cooler to radiator. Torque fasteners to 8 Nm (70 in.lbs).






5. Install radiator fan/shroud assembly. Hand start fasteners.

6. Torque all condenser fasteners to 8 Nm (70 in.lbs).

7. Torque all radiator fan fasteners to 6 Nm (55 in.lbs)

8. NON-TURBO VEHICLES WITH AUTOMATIC TRANSMISSION: Install fasteners attaching transmission oil cooler to radiator. Torque fasteners to 8 Nm (70 in.lbs).

9. Raise vehicle on hoist.

10. NON-TURBO VEHICLES: Connect the lower air seal to the side air seals.






11. Connect lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.







12. Connect the radiator fan electrical connector.

13. TURBO VEHICLES: Connect the power steering hoses.

14. Close radiator draincock.

15. Lower vehicle.

16. TURBO VEHICLES: Inspect radiator inlet neck o-ring. Replace if necessary. Install radiator inlet neck. Torque fasteners to 6 Nm(55 in.lbs).

17. Connect upper radiator hose. Align the hose and position the clamp to prevent interference with the engine or hood.






18. Install upper radiator closure panel and center brace.

19. Install grille.

20. Install battery tray and battery.

21. Connect positive battery cable. Connect negative battery cable.

22. Install air cleaner housing assembly.

23. Fill cooling system with coolant, refer to Service and Repair

24. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

25. TURBO VEHICLES: Check power steering fluid level. Fill as needed.