Radiator Replacement

Radiator Replacement

Removal Procedure





1. Remove the radiator air upper baffle retainers.
2. Remove the radiator air upper baffle.





3. Remove the radiator inlet hose.
4. Remove the radiator outlet hose.
5. Remove the lower fan shroud.
6. Reposition the surge tank hose clamp at the radiator.
7. Remove the surge tank hose from the radiator.





8. Disengage the plastic caps from the quick connect fitting. Pull the caps back along the pipe.
9. Hold one leg of the retaining clip.
10. Using a small pick-type tool (or bent screwdriver), gently pull the other end of the retaining clip from the quick connect fitting.
11. Rotate the retaining clip out of the quick connect fitting.
12. Remove the retaining clip completely.
13. Discard the OLD retaining clip.
14. Perform the above steps for all quick connect fittings on the radiator.





15. Gently, pull the transmission oil cooler pipes straight out from the radiator quick connect fittings.





16. Remove the radiator bolts.
17. Lift the radiator from the lower mounting brackets on the charged air cooler.
18. Remove the radiator from the vehicle.

Installation Procedure





1. Install the radiator until the lower mounts are in the brackets on the charged air cooler.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the radiator bolts.
^ Tighten the radiator bolts to 25 Nm (18 ft. lbs.).
3. If a NEW radiator is being installed, proceed to step 10.
4. If the OLD radiator is to be re-installed, proceed to the next step.





5. Install NEW retaining clips into the quick connect fittings. Do not install the retaining clips onto the fittings by pushing on the clip.

Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to the engine.

6. Install the NEW retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the new retaining clip into one of the three recesses. Ensure that the retaining clip is engaged in all 3 slots.





7. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place.





8. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots.
9. Install NEW retaining clips into the remaining quick connect fittings.





Important: Ensure the transmission oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation.

10. Install the transmission oil cooler line straight into the quick connect fitting.
Insert the cooler line end into the quick connect fitting until a click is either heard of felt.





Important: Do not use the plastic cap in order to install the cooler line into the fitting.

11. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting.





Important: Do not manually depress the retaining clip when installing the plastic cap.

12. Snap the plastic cap onto the quick connect fitting.
13. Ensure that the plastic cap is fully seated against the fitting.





14. Ensure that no gap is present between the cap and the fitting.





15. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating.





16. Install the surge tank hose to the radiator.
17. Position the surge tank hose clamp at the radiator.





18. Install the lower fan shroud.
19. Install the radiator outlet hose.
20. Install the radiator inlet hose.





21. Install the radiator air upper baffle.
22. Install the radiator air upper baffle retainers.