Removal and Installation

REMOVAL
1. Disconnect battery negative cables.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.

2. Drain the cooling system.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter.

3. Remove hose clamps and hoses from radiator.
4. Remove coolant reserve/overflow tank hose from radiator filler neck nipple.
5. The coolant recovery/reservoir does not require removal. Disconnect the overflow hose from the radiator.
6. Disconnect electrical connectors at windshield washer reservoir tank and remove tank. Refer to Wiper and Washer Systems for procedures.






7. Remove the four fan shroud mounting bolts. Position shroud rearward over the fan blades towards engine.






8. Remove the two radiator upper mounting bolts.
9. Lift radiator straight up and out of engine compartment. The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower radiator support panel. Rubber his cults (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser when removing.

INSTALLATION
1. Position fan shroud over the fan blades rearward towards engine.
2. Install rubber insulators to alignment dowels at lower part of radiator.
3. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application.
4. Install two upper radiator mounting bolts. Tighten bolts to 11 Nm (95 in. lbs.) torque.
5. Connect both radiator hoses. Refer to previous CAUTION and install hose clamps.
6. Install windshield washer reservoir tank.
7. Position fan shroud to flanges on sides of radiator. Install fan shroud mounting bolts. Tighten bolts to 6 Nm (50 in. lbs.) torque.
8. Install coolant reserve/overflow tank hose to radiator filler neck nipple.
9. Connect the overflow hose to the radiator.
10. Install battery negative cables.
11. Position heater controls to full heat position.
12. Fill cooling system with coolant.
13. Operate engine until it reaches normal temperature. Check cooling system fluid levels.