Radiator: Service and Repair

Radiator Replacement (Diesel)

Tools Required

J 38185 Hose Clamp Pliers

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.




1. Remove the air cleaner assembly.
2. Remove the upper radiator baffle.
3. Remove the surge tank.
4. Remove battery.
5. Remove the charged air cooler inlet hose/pipe.




6. Remove the clamp at the radiator inlet using the J 38185.
7. Remove the radiator inlet hose (5) from the radiator.
8. Remove the outlet heater hose clamp at the radiator using the J 38185.
9. Remove the outlet heater hose (2) from the radiator.
10. Remove the automatic transmission cooler lines.
11. Remove the engine oil cooler lines.
12. Remove the engine oil fill tube.
13. Remove intake manifold tube.




14. Remove the upper radiator baffle.
Remove the fan shroud bolts (1) from the top of the radiator support.
15. Remove the fan shroud bolts (3) from the sides of the fan shroud.




16. Remove the radiator mounting bolts from the charged air cooler.
17. Remove the charge air cooler bolts to core support.
18. Remove the radiator and charge air cooler as assembly.
19. Remove radiator bolts to charge air cooler.
20. Remove the radiator insulators.
21. Inspect the following components:
^ The radiator
^ The insulators
^ The hoses and clamps
^ The mounting hardware
Replace the components as necessary.

Installation Procedure




1. Install the radiator insulators.

Notice: Refer to Fastener Notice.

2. Install the radiator to the charge air cooler.

Tighten the bolts to 6 N.m (53 lb in).

3. Install the radiator and charge air cooler as an assembly.
4. Install the radiator mounting bolts to the charged air cooler.

Tighten the bolts to 6 N.m (53 lb in).




5. Install the fan shroud bolts (1) to the top of the radiator support.

Tighten the bolts to 6 N.m (53 lb in).

6. Install the fan shroud bolts (3) to the sides of the fan shroud.

Tighten the bolts to 6 N.m (53 lb in).

7. Install the engine oil cooler lines.
8. Install the automatic transmission oil cooler lines.




9. Install the radiator inlet hose (5) to the radiator.
10. Install the hose clamp at the radiator inlet housing using the J 38185.
11. Install the outlet heater hose (2).
12. Install the outlet heater hose clamp using the J 39529.
13. Install the intake manifold tube.
14. Install oil fill tube. Oil Fill Tube Replacement.
15. Install the upper radiator baffle.
16. Install the battery.
17. Install the charged air cooler hose/pipe.
18. Install the surge tank assembly.
19. Install the air cleaner assembly.




20. Install the upper radiator baffle.
21. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities.
22. Inspect the engine oil level. Refer to Approximate Fluid Capacities.