- Disconnect battery negative cable.
- Remove radiator pressure cap.
- For access to radiator draincock, remove radiator grill mounting screws and remove grill.
- Attach one end of a 24 inch long x 1 / 4 inch ID hose to the radiator petcock Put the other end into a clean container. Open petcock and drain radiator.
- Detach power steering fluid reservoir from fan shroud and lay aside.
- Disconnect electric cooling fan electrical connector, if equipped
- Disconnect CRS hose from radiator filler neck and remove from shroud retaining loops.
- Remove the four (4) viscous fan/drive assembly nuts from the water pump pulley and remove fan/drive assy.
- Remove the four (4) fan shroud to core support mounting screws.
- Remove the electric fan (if equipped) and shroud assembly from the vehicle
- Remove radiator upper crossmember.
- If equipped with air conditioning, separate radiator from condenser by removing condenser-to-radiator mounting brackets.
- Disconnect upper and lower radiator hoses.
- If equipped, disconnect and plug automatic transmission fluid cooler lines. Quick Connect Fitting Release Tool 6935 may be needed. If equipped with remote transmission cooler, remove line to cooler from bracket at bottom of radiator
- Lift radiator straight up and out of engine compartment taking care not to damage fins.
If radiator is to be replaced, be sure to remove and transfer any components not included with replacement radiator.
- The radiator is supplied with two alignment dowels. They are located on the bottom tank and fit into rubber grommets in the radiator lower crossmember.
- Lower radiator into engine compartment. Position alignment dowels into rubber grommets in radiator lower crossmember.
- If equipped with air conditioning, attach condenser to radiator with mounting brackets
- Install radiator upper crossmember and four mounting bolts.
- Install radiator upper crossmember-to-isolator nuts. Tighten nuts to 86 inch lbs. (10 Nm) torque. If isolator-to-radiator nuts had been removed, tighten them to 47 inch lbs. (5 Nm).
- Connect radiator upper and lower hoses.
- If equipped, connect automatic transmission fluid cooler lines. If equipped with remote cooler, attach cooler line to bracket at bottom of radiator.
- Install electric fan (if equipped) and shroud assembly. Insert alignment tabs at bottom of fan shroud into slots in bracket at bottom of radiator. Tighten mounting bolts to 31 inch lbs. (3 Nm).
- Connect electric cooling fan electrical connector.
- Install power steering reservoir to fan shroud.
- Install grill.
- Connect battery negative cable.
- Fill cooling system with correct coolant.
- Install pressure cap.
- Check and adjust automatic transmission fluid level (if equipped)
- Start engine and visually check for leaks.
- Disconnect the negative battery cable at battery.
- Drain coolant from radiator.
- Remove the front grill.
- Remove two radiator mounting bolts.
- Disconnect both transmission cooler lines from radiator.
- Disconnect electrical connector for the fan control solenoid.
- Disconnect the power steering cooler line from cooler and filter.
- Disconnect the radiator upper and lower hoses.
- Disconnect the overflow hose from radiator.
- Remove the air inlet duct at the grill.
The lower part of radiator is equipped with two alignment dowel pins. They are located on the bottom of radiator tank and fit into rubber grommets. These rubber grommets are pressed into the radiator lower crossmember.
WARNINGThe air conditioning system (if equipped) is under a constant pressure even with the engine off.
NOTEThe radiator and radiator cooling fan can be removed as an assembly. It is not necessary to remove the cooling fan before removing or installing the radiator.
- Disconnect the two high pressure fluid lines at the hydraulic fan drive.
- Disconnect the low pressure return hose at the hydraulic fan drive.
- Gently lift up and remove radiator from vehicle. Be careful not to scrape the radiator fins against any other component. Also be careful not to disturb the air conditioning condenser (if equipped).
Before installing the radiator or A/C condenser, be sure the radiator-to-body and radiator-to-A/C condenser rubber air seals are properly fastened to their original positions. These are used at the top, bottom and sides of the radiator and A/C condenser. To prevent overheating, these seals must be installed to their original positions.
- Equipped with air conditioning: Gently lower the radiator and fan shroud into the vehicle. Guide the two radiator alignment dowels through the holes in the rubber air seals first and then through the A/C support brackets. Continue to guide the alignment dowels into the rubber grommets located in lower radiator crossmember. The holes in the L-shaped brackets (located on bottom of A/C condenser) must be positioned between bottom of rubber air seals and top of rubber grommets.
Connect the radiator upper and lower hoses and hose clamps to radiator.
CAUTIONThe tangs on the hose clamps must be positioned straight down.
- Install coolant reserve/overflow tank hose at radiator.
- Connect both transmission cooler lines at the radiator.
- Install both radiator mounting bolts.
- Install air inlet duct at grill.
- Attach electric connector for hydraulic fan control solenoid.
- Install the grill.
- Connect the two high pressure lines to the hydraulic fan drive. Tighten 1 / 2 in. pressure line fitting to 36 ft. lbs.(49 Nm) and the 3 / 8 in. pressure line fitting to 21.5 ft. lbs. (29 Nm).
- Connect the low pressure hose to the hydraulic fan drive. Position the spring clamp.
- Connect the power steering filter hoses to the filter. Install new hose clamps.
- Rotate the fan blades (by hand) and check for interference at fan shroud.
- Refill cooling system.
- Refill the power steering reservoir and bleed air from system.
- Connect battery cable at battery.
- Start and warm engine. Check for leaks.