Radiator: Service and Repair
RADIATOR - 5.9L DIESELREMOVAL
1. Disconnect both 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 air box and turbocharger inlet tube.
4. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator.
5. Remove hose clamps and hoses from radiator.
6. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way.
7. Disconnect the transmission cooler lines at the transmission. The transmission cooler will remain on the radiator and can be removed as an assembly.
8. Remove the lower shroud assembly and the electronic viscous fan wiring from the upper shroud assembly.
9. Remove the two radiator upper mounting bolts.
10. 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 biscuits (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser when removing.
CLEANING
Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris.
INSPECTION
Inspect the radiator side tanks for cracks, broken or missing fittings also inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals.
Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes.
INSTALLATION
1. Install rubber insulators to alignment dowels at lower part of radiator.
2. 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.
3. Install two upper radiator mounting bolts. Tighten bolts to 11 Nm (95 in. lbs.) torque.
4. Connect both radiator hoses and install hose clamps.
5. Connect transmission cooler lines to radiator tank. Inspect quick connect fittings for debris and install until an audible "click" is heard. Pull apart to verify connection.
6. Position power steering cooler on the radiator and tighten nuts to 8.5 Nm (75 in. lbs.)
7. Attach electronic viscous fan wiring to upper shroud ends install lower shroud.
8. Position coolant recover tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator.
9. Install air box and turbocharger inlet hose. Tighten clamps to 4 Nm (35 in. lbs.).
10. Position heater controls to full heat position.
11. Fill cooling system with coolant.
12. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels.