Radiator: Service and Repair

REMOVAL

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

1. Disconnect negative battery cable at battery.
2. Observe the previous WARNING. Remove the radiator cap.





3. Remove the condenser lower seal from the lower core support.
4. Drain cooling system drain coolant into a clean container for reuse.
5. Remove radiator upper and lower hose clamps. Remove radiator hoses.
6. Disconnect coolant reserve/overflow tank hose from radiator.





7. Remove the four fan shroud mounting bolts. On some models the power steering fluid reservoir tank is attached to the side of the fan shroud. Tie the reservoir back to prevent spillage. Position the fan shroud back over the fan blades.
8. If equipped, disconnect and plug automatic transmission fluid cooler lines.
9. Remove six radiator mounting bolts. Position the front axle vent hose to the side.
10. Lift radiator straight up and out of vehicle taking care not to damage radiator fins.
11. When removing radiator, note position of the rubber seals located on the top and bottom of radiator (on certain models only). To prevent possible overheating, these seals must be installed to their original positions.

CLEANING
Clean radiator fins. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.

INSPECTION
The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.

INSTALLATION





1. Position the radiator. Install and tighten the six mounting bolts to 8 Nm (72 inch lbs.) torque.
2. Close radiator draincock.
3. Position fan shroud and power steering reservoir tank (if equipped). Install and tighten four mounting bolts to 8 Nm (72 inch lbs.) torque.
4. If equipped, remove plugs and connect automatic transmission fluid cooler lines and constant tension clamps.
5. Connect radiator hoses and install hose clamps.





6. Position and install the condenser lower seal.
7. Connect battery negative cable.
8. Fill cooling system with correct coolant.
9. Connect coolant recovery bottle hose.
10. Install radiator cap.
11. Check and adjust automatic transmission fluid level (if equipped).
12. Start engine and check for leaks.