Chrysler Full-Size Vans 1989-1998 Repair Guide

Radiator

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REMOVAL & INSTALLATION



See Figures 1 through 17

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the upper radiator hose from the outlet on the radiator.
  2.  
  3. Disconnect the coolant reservoir hose from the radiator.
  4.  
  5. Remove the fan shrouds from the vehicle.
  6.  
  7. Remove the lower radiator hose from the radiator outlet.
  8.  
  9. Label, disconnect, and cap the transmission cooler lines and the cooler openings to prevent contamination.
  10.  
  11. Remove the radiator top mounting bolts.
  12.  
  13. If equipped with air conditioning, remove the grille and remove the condenser mounting bolts.
  14.  
  15. Remove the lower radiator mounting bolts.
  16.  
  17. Remove the cowl-to-radiator support braces (if equipped).
  18.  

On some vehicles, it may be necessary to remove the hood release cable to remove the radiator from the top.

  1. Remove the radiator by lifting it out the top.
  2.  

Although the manufacturer states to remove the radiator from beneath, we found it easier to remove it from above.

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Fig. Fig. 1: The original equipment clamps can be released using a pair of pliers or equivalent to release the tension



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Fig. Fig. 2: Remove the clamp, if equipped, then twist and pull the overflow reservoir hose from the nipple on the radiator neck



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Fig. Fig. 3: The overflow reservoir and washer solvent bottle are located on the driver's side of the radiator



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Fig. Fig. 4: An exploded view of the radiator and fan shroud mounting



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Fig. Fig. 5: Underneath view of the radiator



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Fig. Fig. 6: Location of the driver side lower fan shroud retaining bolt



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Fig. Fig. 7: Location of the passenger side lower fan shroud retaining bolt



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Fig. Fig. 8: Release the lower radiator hose clamp in the same manner as the upper hose clamp



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Fig. Fig. 9: Use a suitable tool to release the clip in the transmission cooler line connections



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Fig. Fig. 10: When the clip is released, remove and store it to reduce the chance of it getting lost



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Fig. Fig. 11: When the line is released, fluid will likely come out, so place a container beneath it and be prepared to cap or plug the line



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Fig. Fig. 12: Use a suitable cap to close off the line; also, don't forget to seal the radiator opening to prevent cooler contamination



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Fig. Fig. 13: The air cleaner intake tube will need to be removed on some vehicles



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Fig. Fig. 14: Remove the cowl-to-radiator supports to allow clearance for the radiator to be removed



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Fig. Fig. 15: It may be necessary to detach the hood release cable to remove the radiator



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Fig. Fig. 16: View of the radiator after its removal from the vehicle



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Fig. Fig. 17: After removal, check the radiator for damage and signs of leaks

To install:
  1. Carefully lower the radiator into place.
  2.  
  3. Install and tighten the mounting bolts to 95 inch lbs. (11 Nm).
  4.  
  5. Install the condenser mounting bolts (if equipped).
  6.  
  7. Install the grille (if necessary).
  8.  
  9. Install the lower radiator hose.
  10.  
  11. Connect the transmission cooler lines.
  12.  
  13. Install the fan shrouds. Tighten the mounting nuts to 95 inch lbs. (11 Nm).
  14.  
  15. Install the upper radiator hose.
  16.  
  17. Install the coolant reservoir hose.
  18.  
  19. Install the cowl-to-radiator support braces (if necessary).
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Refill and bleed the cooling system.
  24.  
  25. Start the vehicle and run it until it reaches normal operating temperature.
  26.  
  27. Check the transmission fluid level.
  28.  
  29. Check the vehicle for leaks.
  30.  

 
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