Radiator: Service and Repair

REMOVAL
1. Disconnect negative cable from battery.

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

2. Drain cooling system.
3. Remove air intake resonator.
4. Remove coolant reserve/recovery system container to filler neck tube hose.
5. Disconnect electrical connector from cooling fans. Connector is located on the left side of the fan module.
6. Remove the Coolant Recovery System (CRS) container retaining screw from the upper radiator closure panel crossmember.
7. Disconnect the upper radiator mounting screws from the crossmember.
8. Disconnect the engine block heater wire, if equipped.
9. Remove the upper radiator closure panel crossmember.
10. Remove air cleaner assembly.
11. Disconnect automatic transmission oil cooler lines at radiator. Plug cooling lines to prevent excessive spillage.
12. Disconnect coolant inlet and outlet hoses from the radiator. Remove the lower hose clip from the fan module.






13. Remove A/C condenser fasteners and separate the condenser from the radiator. Verify the condenser is supported in position.
14. Remove A/C filter/dryer mounting bracket, two bolts to the fan module, and two nuts to the filter/dryer.
15. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

INSTALLATION
1. Be sure the air seals are in position before radiator is installed. Slide radiator down into position behind closure panel. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force.
2. Install A/C filter/dryer and mounting bracket onto fan module.
3. Install air conditioning condenser onto the radiator.
4. Unplug and connect automatic transmission oil cooler lines to radiator.
5. Install coolant inlet and outlet radiator hoses (including coolant reserve/recovery hose) and connect the fan motor electrical connector.
6. Install air cleaner assembly.
7. Install the upper radiator closure panel crossmember.
8. Install the upper radiator mounting screws. Tighten radiator mounting bolts to 12 Nm (105 inch lbs.).
9. Connect the engine block heater wire, if equipped.
10. Install the Coolant Recovery System (CRS) container retaining screw to the upper radiator closure panel crossmember.
11. Install air intake resonator.
12. Fill cooling system.
13. Connect negative cable to battery.