Radiator Replacement

Radiator Replacement

Removal Procedure

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.


Some assemblies are equipped with an engine oil cooler and/or an automatic transmission oil cooler in the side tanks. Before you remove the oil cooler lines, provide a container to catch the oil that is drained from the cooler and the lines. Do not reuse the drained fluid.

1. Remove the front wheelhouse panel. Refer to Wheelhouse Panel Replacement Service and Repair in Body Front End.




2. Remove the front intake air duct (1) from the air filter housing.
3. Drain the coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
4. Remove the upper radiator hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.
5. Remove the coolant recovery hoses or the surge tank hose(s) from the radiator.
6. Remove the surge tank mount, if equipped. Refer to Surge Tank (Diesel) Replacement Surge Tank (Diesel) Replacement.
7. Remove the automatic transmission cooler lines, if equipped.
8. Remove the engine oil cooler lines and the quick connector fittings, if equipped. Refer to Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement.
9. Remove the lower radiator hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.
10. Remove the heater hose.
11. Remove the fan shroud bolts. Position the fan shroud rearward.
12. Remove the upper air conditioning condenser mounting bolts, if equipped.




13. Remove the radiator upper mounting panel bolts.
14. Remove the radiator upper mounting panel (1).
15. Remove the radiator (3) from the lower mounting panel (2).
16. Remove the radiator insulators.
17. Inspect the following components:

* The radiator
* The hoses
* The mounting hardware
Replace the components as necessary.

Installation Procedure

1. Install the radiator insulators.




2. Install the radiator (3) into the lower mounting panel (2).
3. Install the radiator upper mounting panel (1).

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the radiator upper mounting panel bolts.

Tighten the upper mounting panel bolt to 25 Nm (18 lb ft).

5. Install the upper air conditioning condenser mounting bolts, if equipped.

Tighten the air conditioning condenser mounting bolt to 25 Nm (18 lb ft).

6. Install the fan shroud.

Tighten the fan shroud bolts to 6 Nm (53 lb in).

7. Install the engine oil cooler lines and the quick connector fittings, if equipped.

* Tighten the engine oil cooler hose fitting to radiator to 60 Nm (44 lb ft).
* Tighten the engine oil cooler quick connector-to-hose fitting to 35 Nm (26 lb ft).

8. Install the automatic transmission oil cooler lines, if equipped.

Tighten the transmission cooler line fitting to 30 Nm (22 lb ft).

9. Install the lower radiator hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.
10. Install the heater hose.
11. Connect the coolant recovery hose(s) or the surge tank hose(s) to the radiator.
12. Install the upper radiator hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.
13. Install the front wheelhouse panel. Refer to Wheelhouse Panel Replacement Service and Repair in Body Front End.




14. Connect the front intake air duct (1) to the air filter housing.
15. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
16. Fill the automatic transmission to the proper capacity, if equipped. Refer to Approximate Fluid Capacities [1][2]Capacity Specifications in Automatic Transmission.
17. Inspect the system for leaks.