Radiator Replacement LY7 - Standard Cooling

special Tools

1. Drain the coolant. Refer to Cooling System Draining and Filling.
2. Remove the electric cooling fan assembly. Refer to Engine Coolant Fan Replacement.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



4. Remove the lower condenser mounting bolts.



5. Remove the upper condenser mounting bolts.




Note: Reposition the condenser to access the transmission oil cooler mounting bolts.

6. Remove the transmission oil cooler mounting bolts.



7. Disconnect the side air baffle lower retainer pins from the radiator.
8. Lower the vehicle.
9. Remove the radiator support bracket bolts.
10. Remove the radiator support brackets.
11. Remove the radiator/condenser upper support using J 38778 Door Trim Pad Clip Remover .



12. Disconnect the surge tank inlet hose from the radiator using the J 38185 Hose Clamp Pliers and reposition aside.



13. Using the J 38185 Hose Clamp Pliers disengage tension on the radiator inlet hose clamp (1) and disconnect from the radiator.
14. Using the J 38185 Hose Clamp Pliers disengage tension on the radiator outlet hose clamp and disconnect from the radiator.
15. Disconnect the side air baffle upper retainer pins from the radiator.
16. Remove the radiator.

1. Install the radiator.
2. Connect the side air baffle upper retainer pins to the radiator.
3. Connect the radiator outlet hose to the radiator and using the J 38185 Hose Clamp Pliers , position the radiator outlet hose clamp to secure the hose.



4. Connect the radiator inlet hose (2) to the radiator and using the J 38185 Hose Clamp Pliers , position the radiator inlet hose clamp (1) to secure the hose.



5. Connect the surge tank inlet hose to the radiator and using the J 38185 Hose Clamp Pliers , position the hose clamp to secure the hose.
6. Install the radiator/condenser upper support.
7. Install the radiator support brackets.

Caution: Refer to Fastener Caution in the Preface section.

8. Install the radiator support bracket bolts and tighten to 9 N·m (80 lb in).
9. Raise and support the vehicle.



10. Connect the side air baffle lower retainer pins to the radiator.



11. Install the transmission oil cooler mounting bolts and tighten to 5 N·m (44 lb in).



12. Install the upper condenser mounting bolts and tighten to 6.5 N·m (58 lb in).



13. Install the lower condenser mounting bolts and tighten to 6.5 N·m (58 lb in).
14. Lower the vehicle.
15. Install the electric cooling fan assembly. Refer to Engine Coolant Fan Replacement.
16. Fill the cooling system. Refer to Cooling System Draining and Filling.

Radiator Replacement LH2 - Standard Cooling

Special Tools

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling.
2. Remove the electric cooling fan. Refer to Engine Coolant Fan Replacement.



3. Remove the upper condenser mounting bolts.



4. Remove the lower condenser mounting bolts.



5. Disconnect the side air baffle lower retaining pins from the radiator.

Note: Reposition the condenser to access the transmission oil cooler mounting bolts.

6. Remove the transmission oil cooler (TOC) mounting bolts.
7. Lower the vehicle.



8. Using the J 38185 Hose Clamp Pliers , disengage the tension on the hose clamp (1) and remove the radiator outlet hose (2) from the radiator.



9. Using the J 38185 Hose Clamp Pliers , disengage the tension on the hose clamp (1) and remove the radiator inlet hose (2) from the radiator.



10. Using the J 38185 Hose Clamp Pliers , disengage the tension on the hose clamp and remove the surge tank inlet hose from the radiator.



11. Remove the radiator support bracket bolts.
12. Remove the radiator support brackets.
13. Disconnect the upper air baffle retaining pins from the radiator.
14. Remove the radiator.

1. Install the radiator.
2. Connect the upper air baffle retaining pins to the radiator.
3. Install the radiator support brackets.

Caution: Refer to Fastener Caution in the Preface section.




4. Install the radiator support bracket bolts and tighten to 9 N·m (80 lb in).



5. Connect the surge tank inlet hose to the radiator and using the J 38185 Hose Clamp Pliers , position the surge tank inlet hose clamp to secure the hose.



6. Connect the radiator inlet hose (2) to the radiator and using the J 38185 Hose Clamp Pliers , position the radiator inlet hose clamp (1) to secure the hose.



7. Connect the radiator outlet hose (2) to the radiator and using the J 38185 Hose Clamp Pliers , position the radiator outlet hose clamp (1) to secure the hose.
8. Raise and support the vehicle.
9. Install the TOC mounting bolts and tighten to 5 N·m (44 lb in).



10. Connect the side air baffle lower retaining pins to the radiator.



11. Install the lower condenser mounting bolts and tighten to 6.5 N·m (58 lb in).



12. Install the upper condenser mounting bolts and tighten to 6.5 N·m (58 lb in).
13. Install the electric cooling fan. Refer to Engine Coolant Fan Replacement.
14. Fill the cooling system. Refer to Cooling System Draining and Filling.

Radiator Replacement LH2 - Heavy Duty Cooling

Special Tools

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling.
2. Remove the electric cooling fan. Refer to Engine Coolant Fan Replacement.



3. Remove the upper condenser mounting bolts.



4. Remove the lower condenser mounting bolts.



5. Disconnect the side air baffle lower retaining pins from the radiator.

Note: Reposition the condenser to access the transmission oil cooler mounting bolts.

6. Remove the transmission oil cooler (TOC) mounting bolts.
7. Lower the vehicle.
8. Remove the fan shroud. Refer to Engine Coolant Fan Shroud Replacement.
9. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the radiator.



10. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the radiator.



11. Using the J 38185 , disengage the tension on the hose clamp and remove the surge tank inlet hose from the radiator.



12. Remove the radiator support bracket bolts.
13. Remove the radiator support brackets.
14. Disconnect the upper air baffle retaining pins from the radiator.
15. Remove the radiator.

1. Install the radiator.
2. Connect the upper air baffle retaining pins to the radiator.
3. Install the radiator support brackets.

Caution: Refer to Fastener Caution in the Preface section.




4. Install the radiator support bracket bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).




5. Connect the surge tank inlet hose to the radiator and using the J 38185 , position the surge tank inlet hose clamp to secure the hose.



6. Connect the radiator inlet hose to the radiator and using the J 38185 , position the radiator inlet hose clamp to secure the hose.
7. Connect the radiator outlet hose to the radiator and using the J 38185 , position the radiator outlet hose clamp to secure the hose.
8. Install the fan shroud. Refer to Engine Coolant Fan Shroud Replacement.
9. Raise and support the vehicle.
10. Install the TOC mounting bolts.

Tighten
Tighten the bolts to 5 N·m (44 lb in).




11. Connect the side air baffle lower retaining pins to the radiator.



12. Install the lower condenser mounting bolts.

Tighten
Tighten the bolts to 6.5 N·m (58 lb in).




13. Install the upper condenser mounting bolts.

Tighten
Tighten the bolts to 6.5 N·m (58 lb in).

14. Install the electric cooling fan. Refer to Engine Coolant Fan Replacement.
15. Fill the cooling system. Refer to Cooling System Draining and Filling.