Removal and Installation

REMOVAL
(1) Disconnect the battery negative cable.

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) Raise vehicle on hoist.
(3) 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) 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.

(4) Remove the radiator lower hose from the radiator outlet.






(5) Disconnect the transmission oil cooler lines from the radiator fittings using the quick connect release tool #6935. Cap the lines to prevent intrusion of foreign matter and secure the lines out of the way.
(6) Lower the vehicle.
(7) Remove the engine oil filler tube.
(8) Remove the radiator upper support-to-cowl brackets.
(9) Remove coolant reserve/overflow tank hose from radiator filler neck fitting.
(10) Remove the windshield washer bottle.






(11) Remove the coolant recovery bottle.
(12) Disconnect the radiator upper hose from the radiator inlet.






(13) Remove fan shroud mounting bolts and position shroud rearward on engine.
(14) Remove radiator mounting bolts.
(15) Lift the radiator up and out of the engine compartment. Be careful not to damage the radiator fins or core.

INSTALLATION
(1) Position fan shroud rearward on engine.
(2) Start the radiator lower mounting bolts by hand (do not tighten).
(3) Lower radiator into engine compartment until the lower mounting slots rest upon the previously installed mounting bolts.
(4) Start the radiator upper mounting bolts and tighten all mounting bolts to 11 Nm (95 inch lbs.).
(5) Position fan shroud on radiator flange. Tighten mounting nuts to 6 Nm (50 inch lbs.).
(6) Raise vehicle on hoist.
(7) Install the radiator lower hose and clamp to the radiator outlet.
(8) Remove protective caps from the transmission oil cooler lines. Inspect for damage and/or debris and install to radiator fittings until an audible "click" is heard. Verify connection by pulling outward on fittings.
(9) Lower the vehicle.
(10) Install the radiator upper hose and clamp to the radiator inlet,
(11) Install the coolant recovery bottle. Engage the tab on bottom with the slot in the radiator mounting panel. Install the two mounting bolts and torque to 6 Nm (50 inch lbs.).
(12) Connect the coolant reserve/overflow system hose to the radiator filler neck.
(13) Install the windshield washer reservoir.
(14) Install the radiator upper support-to-cowl brackets.
(15) Install the engine oil filler tube.
(16) Fill cooling system with coolant.
(17) Operate engine until it reaches normal temperature and bleed heater hose if necessary. Check cooling system and automatic transmission fluid levels.