Radiator Replacement
Radiator Replacement (L77)
Special Tools
J 41623-B Quick Connect Release Tool
Removal Procedure
Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.
1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
Warning:
Refer to Radiator Cap Removal Warning Service Precautions.
2. Ensure engine is below 50 C before removing the coolant pressure cap.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.
3. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
4. Place a suitable container beneath the radiator and engine.
5. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
6. Remove the air deflector.
7. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LFX) Radiator Outlet Hose ReplacementRadiator Outlet Hose Replacement (L77) Radiator Outlet Hose Replacement.
8. Remove the condenser to radiator lower mounting fastener (1).
9. Remove the lower transmission cooler bracket fasteners to the radiator (2).
10. Lower the vehicle.
11. Remove the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
12. Remove the mass air flow sensor. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Service and Repair.
13. Remove the radiator inlet hose from the radiator.
14. Remove the coolant recovery reservoir hose (1) from the coolant pressure cap (2).
15. Remove the coolant air bleed hose from the radiator. Refer to Engine Coolant Air Bleed Hose Replacement (V6) Engine Coolant Air Bleed Hose ReplacementEngine Coolant Air Bleed Hose Replacement (V8) Engine Coolant Air Bleed Hose Replacement.
Note:
When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.
16. Using the cooler quick connect tool J 41623-B disconnect the transmission cooler lines (2) from the flexible hoses (1).
* Detach plastic cover from hose fitting and slide along pipe.
* Open the cooler quick connect tool J 41623-B then close and clip around the hose to be disconnected.
* While holding the flexible hoses (1) push the hoses inwards with one hand, then pull back to separate from the steel transmission cooler lines (2).
* Repeat procedure for the second fitting.
17. Remove the radiator upper mount fasteners (1).
18. Remove the radiator upper mounts (2).
19. Disconnect the cooling fans electrical connector (2) from the main wiring loom connector (1).
20. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement.
21. Remove the two radiator to upper condenser fasteners (1).
22. Remove the two upper radiator to transmission cooler bracket fasteners (1).
23. Tilt the radiator (1) forward and remove the radiator assembly from the vehicle.
Installation Procedure
1. Install the radiator (1) into the lower insulators located in the cross member.
2. Install the two upper radiator to transmission cooler bracket fasteners (1) and tighten to 11 Nm (97 lb in).
3. Install the two radiator to upper condenser fasteners (1) and tighten to 11 Nm (97 lb in).
4. Install the condenser to radiator lower mounting fastener (1) and tighten to 11 Nm (97 lb in).
5. Install the lower transmission cooler bracket fasteners to the radiator (2) and tighten to 11 Nm (97 lb in).
6. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement.
7. Connect the cooling fans electrical connector (2) to the main wiring loom connector (1).
8. Install the radiator upper mount (2).
9. Install the radiator upper mounts fasteners (1).
Note:
Ensure cloth is removed before carrying out installation procedure.
10. Connect the flexible hoses (1) to the transmission cooler lines (2), listen for an audible click to confirm fitting.
11. Push plastic cover forward along pipe and clip onto hose fitting.
12. Install the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement (V6) Engine Coolant Air Bleed Hose ReplacementEngine Coolant Air Bleed Hose Replacement (V8) Engine Coolant Air Bleed Hose Replacement.
13. Install the coolant recovery reservoir hose (1) to the coolant pressure cap (2).
14. Install the radiator inlet hose.
15. Install the mass air flow sensor.
16. Install the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.
17. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
18. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LFX) Radiator Outlet Hose ReplacementRadiator Outlet Hose Replacement (L77) Radiator Outlet Hose Replacement.
19. Install the air deflector.
20. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
21. Install the condenser to radiator lower mounting fastener (1) and tighten to 11 Nm (97 lb in).
22. Install the lower transmission cooler bracket fasteners to the radiator (2) and tighten to 11 Nm (97 lb in).
23. Lower the vehicle.
24. Install the battery ground lead to the vehicle. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
25. Inspect cooling system for leaks.