Radiator

Radiator - 6.0L Diesel

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Cooling System Draining, Filling and Bleeding.

3. Remove the 6 pushpin retainers and upper air deflector.





4. Remove the 4 bolts for the power steering reservoir bracket.





5. Remove the 3 bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.





6. Disconnect the coolant hoses from the Air Cleaner (ACL) outlet tube.





7. NOTE: ACL side shown, other side similar.

Loosen the 2 clamps and remove the ACL outlet pipe.





8. Disconnect the Mass Air Flow (MAF) sensor electrical connector. Disconnect the 3 clips and remove the ACL cover.





9. Loosen the clamps and remove the Charge Air Cooler (CAC) tube.





10. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC hose to prevent the hose from blowing off.

Loosen the clamps and remove the CAC hose.





11. Disconnect the radiator vent hose.

12. Disconnect and remove the upper radiator hose.





13. Remove the 4 bolts and lower air deflector.





14. Disconnect the transmission cooler hoses.
- Plug or cap the hoses as needed.





15. Disconnect the lower radiator hose.

16. Remove the 2 lower shroud bolts.

17. Disconnect the transmission cooler hoses from the lower shroud and remove the lower shroud.





18. Remove the 2 pushpin retainers and the closeout.





19. NOTE: LH side shown, RH side similar.

Remove the 4 bolts and the radiator mounting brackets.





20. NOTE: Cooling module removed from vehicle for clarity.

Remove the 2 bolts and fan shroud.





21. NOTE: LH side shown, RH side similar.

Remove the 2 A/C condenser bolts.





22. NOTICE: Make sure the transmission cooler fittings on the radiator are not contacting the A/C condenser or damage to the A/C condenser may occur.

With the help of an assistant, raise the radiator and CAC as an assembly enough to separate the A/C condenser from the CAC. Remove the radiator and CAC as an assembly from the vehicle.

Installation

1. With the help of an assistant, position the radiator and CAC into the vehicle.

2. From the bottom of the vehicle, connect the A/C condenser to the CAC and position the entire assembly into place.

3. NOTE: LH side shown, RH side similar.

Install the 2 A/C condenser bolts.

- Tighten to 9 Nm (80 lb-in).





4. NOTE: Cooling module removed from vehicle for clarity.

Install the fan shroud and 2 bolts.





5. NOTE: LH side shown, RH side similar.

Install the 4 bolts and the radiator mounting brackets.

- Tighten to 20 Nm (177 lb-in).





6. Install the closeout and 2 pushpin retainers.





7. Install the lower shroud and connect the transmission cooler hoses onto the lower shroud.





8. Install the 2 lower shroud bolts.
- Tighten to 6 Nm (53 lb-in).

9. Connect the lower radiator hose.

10. Connect the transmission cooler hoses.





11. Install the lower air deflector and 4 bolts.





12. Install and connect the upper radiator hose.





13. Connect the radiator vent hose.

14. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC hose to prevent the hose from blowing off.

Install the CAC hose and tighten the 2 clamps.
- Tighten to 12 Nm (106 lb-in).





15. Install the CAC tube and tighten the 2 clamps.
- Tighten to 12 Nm (106 lb-in).





16. Install the ACL cover and connect the 3 clips. Connect the MAF sensor electrical connector.





17. NOTE: ACL side shown, other side similar.

Install the ACL outlet tube and tighten the 2 clamps.





18. Connect the coolant hoses onto the ACL outlet pipe.





19. Remove the power steering fluid indicator. Position the power steering reservoir and install the power steering reservoir mounting bracket. Install the 3 bolts and the power steering fluid indicator.





20. Install the 4 bolts for the power steering reservoir bracket.





21. Install the upper air deflector and 6 pushpin retainers.





22. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Cooling System Draining, Filling and Bleeding.