Radiator Replacement

Radiator Replacement

^ Tools Required
- J 38185 Hose Clamp Pliers
- J 39400-A Halogen Leak Detector

Removal Procedure





1. Recover the refrigerant from the A/C system.
2. Drain the cooling system.
3. Remove the cooling fans with the cooling fan shroud.

Important: Use the J 38185 to gently release tension on the hose clamp until the hose clamp lock feature engages allowing removal of the hose.

4. Release tension from the hose clamp at the water pump housing using the J 38185.
5. Disconnect the radiator outlet hose from the water pump housing.
6. Disconnect the lower TOC line from the radiator.





7. Remove the nut which secures the A/C discharge hose to the condenser block
8. Disconnect the A/C discharge hose from the condenser block.
9. Remove and discard the sealing washer.

Important: Cap or tape off the open A/C hose immediately to prevent system contamination.

10. Cap or tape off the A/C discharge hose.





11. Remove the bolt which secures the evaporator inlet tube to the condenser block.
12. Disconnect the evaporator inlet tube from the condenser block.
13. Cap or tape off the evaporator inlet tube.





14. Remove the radiator and condenser assembly.
15. Release tension from the hose clamp at the radiator using the J 38185.
16. Remove the lower radiator hose.
17. Remove the condenser tube clip bolt.
18. Remove the mounting bolts that secure the condenser to the radiator.
19. Remove the condenser from the radiator.

Installation Procedure





1. Install the condenser to the radiator.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the mounting bolts that secure the condenser to the radiator.
^ Tighten the bolts to 6 Nm (53 inch lbs.).
3. Install the condenser tube clip bolt
^ Tighten the bolt to 2.5 Nm (22 inch lbs.).
4. Install the lower radiator hose.

Important: Release the hose clamp retention lock by using a small flat bladed screwdriver.

5. Release the hose clamp retention lock at the radiator to secure the hose.
6. Install the radiator and condenser assembly.





7. Remove the cap or the tape from the evaporator inlet tube.
8. Install a new sealing washer to the evaporator inlet tube.
9. Install the evaporator inlet tube and the bolt to the condenser block.
^ Tighten bolt to 16 Nm (12 ft. lbs.).





10. Remove the cap or the tape from the A/C discharge hose.
11. Install a new sealing washer to the A/C discharge hose.
12. Install the A/C discharge hose and the nut to the condenser block.
^ Tighten the nut to 16 Nm (12 ft. lbs.).
13. Connect the lower TOC line to the radiator.





14. Connect the radiator outlet hose to the water pump housing.
15. Release the hose clamp retention lock at the water pump housing to secure the hose.
16. Install the cooling fans with the cooling fan shroud.
17. Fill the cooling system.
18. Evacuate and recharge the A/C system.
19. Leak test the fittings of the component using the J 39400-A.
20. Inspect the transmission fluid level.