Radiator Replacement (Heavy Duty Cooling)

Radiator Replacement (Heavy Duty Cooling)

Special Tools
* J 38185 Hose Clamp Pliers
* J 38778 Door Trim Pad Clip Remover

Removal Procedure

1. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill LF1, LLT) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LSA) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 LSA) (Cooling System Draining and Filling (GE 47716))Cooling System Draining and Filling (GE 47716 LF1, LLT) (Cooling System Draining and Filling (GE 47716)).
2. Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LF1, LLT) (Service and Repair)Engine Coolant Fan Shroud Replacement (LSA) (Service and Repair).
3. Remove the front fascia. Refer to Front Bumper Fascia Replacement (Front Bumper Fascia Replacement)
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




5. Remove the lower condenser mounting bolts.




6. Remove the upper condenser mounting bolts.





Note: Reposition the condenser to access the transmission oil cooler mounting bolts.

7. Remove the transmission oil cooler mounting bolts.




8. Disconnect the lower retainer pins of the side air baffle from the radiator.
9. Lower the vehicle.
10. Remove the radiator support bracket bolts.
11. Remove the radiator support brackets.
12. Use J 38778 to remove the radiator/condenser upper support.




13. Use J 38185 to disconnect the surge tank inlet hose from the radiator. Reposition the hose aside.




14. Using J 38185 disengage tension on the radiator inlet hose clamp and disconnect the hose from the radiator.
15. Using J 38185 disengage tension on the radiator outlet hose clamp and disconnect the hose from the radiator.
16. Disconnect the upper retainer pins on the side air baffle from the radiator.
17. Remove the radiator.

Installation Procedure

1. Install the radiator.
2. Connect the upper retainer pins of the side air baffle to the radiator.
3. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.




4. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.




5. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the hose clamp to secure the hose.
6. Install the radiator/condenser upper support.
7. Install the radiator support brackets.

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the radiator support bracket bolts and tighten to 9 Nm (80 lb in).
9. Raise and support the vehicle.




10. Connect the lower retainer pins of the side air baffle to the radiator.




11. Install the transmission oil cooler mounting bolts and tighten to 5 Nm (44 lb in).




12. Install the upper condenser mounting bolts and tighten to 5.4 Nm (48 lb in).




13. Install the lower condenser mounting bolts and tighten to 5.4 Nm (48 lb in).
14. Lower the vehicle.
15. Install the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LF1, LLT) (Service and Repair)Engine Coolant Fan Shroud Replacement (LSA) (Service and Repair).
16. Install the front fascia. Refer to Front Bumper Fascia Replacement (Front Bumper Fascia Replacement)
17. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LF1, LLT) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LSA) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 LSA) (Cooling System Draining and Filling (GE 47716))Cooling System Draining and Filling (GE 47716 LF1, LLT) (Cooling System Draining and Filling (GE 47716)).