Radiator: Service and Repair

RADIATOR REPLACEMENT

Removal Procedure





1. Disconnect the Mass Airflow (MAF) sensor electrical connector (4).
2. Disengage the cover clips (2).
3. Remove the air cleaner cover (1).





4. Loosen the air intake duct clamp at the throttle body.
5. Remove the air intake duct and air cleaner element.
6. Drain the cooling system.





7. If equipped with a 8.1 L engine, reposition the reservoir hose clamp at the radiator.
8. Remove the reservoir hose from the radiator.





9. If equipped with a 6.5L engine, reposition the surge tank inlet hose clamp at the radiator.
10. Remove the inlet hose from the radiator.





11. Reposition the inlet hose clamp (3) at the radiator. (1-18 engine shown, L65 similar).
12. Reposition the outlet hose clamp (4) at the radiator.
13. Remove the inlet (2) and outlet (5) hoses from the radiator.





14. If equipped with a 8.1 L engine, remove the engine oil cooler lines from the radiator.
15. Remove the hose clip from the fan shroud.
16. Remove the transmission oil cooler lines from the radiator.
17. Remove the fan shroud.





18. Remove the radiator mounting bracket bolts and brackets.
19. Remove the radiator.

Installation Procedure
1. Install the radiator.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the radiator mounting brackets and bolts.
Tighten the radiator mounting bracket bolts to 25 Nm (18 ft. lbs.).
3. Install the fan shroud.





4. Install the transmission oil cooler lines to the radiator.
5. If equipped with a 8.1 L engine, install the engine oil cooler lines to the radiator.
6. Install the hose clip to the fan shroud.





7. Install the inlet (2) and outlet (5) hoses to the radiator. (L18 engine shown, L65 similar).
8. Position the outlet hose clamp (4) at the radiator.
9. Position the inlet hose clamp (3) at the radiator.





10. If equipped with a 6.51L engine, install the inlet hose to the radiator.
11. Position the surge tank inlet hose clamp at the radiator.





12. If equipped with a 8.1L engine, install the reservoir hose to the radiator.
13. Position the reservoir hose clamp at the radiator.
14. Fill the cooling system.
15. Install the air intake duct and air cleaner element.





16. Tighten the air intake duct clamp at the throttle body.
Tighten the air intake duct clamp to 3 Nm (26 inch lbs.).





17. Install the air cleaner cover (1).
18. Engage the cover clips (2).
19. Connect the MAF sensor electrical connector (4).