Radiator: Service and Repair

REMOVAL PROCEDURE





1. Drain the coolant from the cooling system.
2. Remove the upper fan shroud.
3. For the 4.3L, 5.OL, and the 5.7L engines, remove the upper insulators and brackets.





4. For the 6.5L and the 7.4L engines, remove the upper insulators and brackets.
5. Disconnect the upper and lower radiator hoses.
6. Remove the transmission fluid cooler pipes.
7. Remove the engine oil cooler pipes.
8. Remove the lower fan shroud bolts and the lower fan shroud.
9. Disconnect the coolant recovery reservoir/surge tank hose.
- Refer to Coolant Recovery Reservoir Replacement.
- For diesel engines, refer to Surge Tank (Diesel) Replacement.





10. For the 4.3L, 5.0L, and the 5.7L, remove the radiator from the lower insulators and brackets.





11. For the 6.5L and the 7.4L, remove the radiator from the lower insulators and brackets.
12. Inspect all of the parts and connections for leaks and wear.
13. Replace the parts and/or connections, as necessary.

INSTALLATION





1. For the 4.3L, 5.0L, and the 5.7L engines, install the radiator on the lower insulators.





2. For the 6.5L and the 7.4L engines, install the radiator on the lower insulators.
3. Install the coolant recovery reservoir/surge tank hose.
- Refer to Coolant Recovery Reservoir Replacement
- For diesel engines, refer to Surge Tank (Diesel) Replacement.

4. Install the lower fan shroud bolts and the lower fan shroud.
Tighten the bolts to 9 Nm (71 inch lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Install the engine oil cooler pipes.
Tighten the fittings to 24 Nm (18 ft. lbs.).

6. Install the transmission fluid cooler pipes.
Tighten the fittings to 26 Nm (19 ft. lbs.).

7. Install the upper and lower radiator hoses.





8. For the 4.3L, 5.0L, and the 5.7L engines, install the upper insulators.





9. For the 6.5L and the 7.4L engines, install the upper insulators.
10. Install the upper fan shroud and the upper fan shroud bolts.
Tighten the bolts to 9 Nm (71 inch lbs.).

11. Refill the coolant in the cooling system.
12. Leak test on the cooling system.