WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REFER TO COOLING SYSTEM DRAINING.
Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C condenser for any reason, note the location of all radiator-to-body and radiator-to-A/C condenser rubber air seals. 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.
Disconnect the negative battery cable at battery.
Drain coolant from radiator. Refer to Cooling System, Service and Repair See: Service and Repair
Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
Remove the front grill. Body and Frame, Grille, Service and Repair See: Body and Frame Grille Service and Repair
Remove two radiator mounting bolts.
Disconnect both transmission cooler lines from radiator.
Disconnect electric fan connector, then disconnect connector harness from shroud.
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.
WARNING: THE AIR CONDITIONING SYSTEM (IF EQUIPPED) IS UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF. REFER TO REFRIGERANT WARNINGS BEFORE HANDLING ANY AIR CONDITIONING COMPONENT.
If equipped with an auxiliary automatic transmission oil cooler, use caution when removing radiator. The oil cooler lines are routed through a rubber air seal on the right side of radiator. Do not cut or tear this seal.
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).
Clean radiator fins with the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.
The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
CAUTION: 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 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.
CAUTION: The 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 fan harness to shroud, then connect harness to connector.
Install the grill. Body and Frame, Grille, Service and Repair See: Body and Frame Grille Service and Repair
Install the fan/viscous fan drive assembly to the water pump.
Rotate the fan blades (by hand) and check for interference at fan shroud.
Be sure of at least 25 mm (1.0 in.) Between tips of fan blades and fan shroud.
Fill cooling system. Refer to Cooling System, Service and Repair See: Service and Repair
Connect battery cable at battery.
Start and warm engine. Check for leaks.