Radiator: Service and Repair

REMOVAL
1. Disconnect negative battery cable at battery.

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

2. Drain the cooling system.





WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL NUMBER 6094. SNAP-ON CLAMP TOOL NUMBER HPC-20, OR EQUIVALENTS MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.





CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.

3. Remove upper radiator hose clamps and hoses from radiator.
4. Remove coolant reserve/overflow tank hose from radiator filler neck fitting.





5. Remove fan shroud mounting bolts and position shroud rearward on engine.
6. Remove radiator top mounting bolts. If equipped with air conditioning, remove the grille to access the condenser mounting bolts.
7. Raise vehicle and disconnect automatic transmission cooler lines.
8. Remove lower radiator hose at radiator. A special clamp tool must be used to remove the constant tension clamps.
9. Remove automatic transmission cooler lines at radiator. Cap or plug oil line openings to prevent entry of dirt and loss of transmission oil.





10. While holding radiator in place, remove the two lower mounting bolts and carefully lower radiator out of the bottom of vehicle.


INSTALLATION
1. Position fan shroud rearward on engine.
2. Carefully raise radiator up into place and install lower attaching bolts. Tighten mounting bolts to 11 Nm (95 inch lbs.) torque.
3. Connect radiator lower hose and transmission oil cooler lines to bottom tank.
4. Install hose clamps on transmission hoses. Tighten to 2 Nm (15 inch lbs.) torque.
5. Lower vehicle. Install radiator upper mounting bolts and (if equipped) air conditioning condenser mounting bolts. Tighten radiator mounting bolts to 11 Nm (95 inch lbs.) torque.
6. Position fan shroud on radiator flange. Tighten mounting nuts to 11 Nm (95 inch lbs.) torque.
7. Connect radiator upper hose and clamp. Connect coolant reserve/overflow system hose.
8. Fill cooling system with coolant.
9. Operate engine until it reaches normal temperature and bleed heater hose if necessary. Check cooling system and automatic transmission fluid levels.