Radiator Replacement LY7 Standard Cooling

Special Tools

Removal Procedure

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 lower retainer pins of the side air baffle from the radiator.
8. Lower the vehicle.
9. Remove the radiator support bracket bolts.
10. Remove the radiator support brackets.
11. Use J 38778 to remove the radiator/condenser upper support.



12. Use J 38185 to disconnect the surge tank inlet hose from the radiator. Reposition the hose aside.



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

Installation Procedure

1. Install the radiator.
2. Connect the upper retainer pins of the side air baffle to the radiator.
3. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.



4. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.



5. Connect the surge tank inlet hose to the radiator. Use J 38185 to 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 lower retainer pins of the side air baffle 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 5.4 N·m (48 lb in).



13. Install the lower condenser mounting bolts and tighten to 5.4 N·m (48 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 Heavy Duty Cooling

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure

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 lower retaining pins of the side air baffle 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. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator outlet hose from the radiator.



10. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator inlet hose from the radiator.



11. Use J 38185 to disengage the tension on the hose clamp. 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.

Installation Procedure

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. Use J 38185 to position the surge tank inlet hose clamp to secure the hose.



6. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.
7. Connect the radiator outlet hose to the radiator. Use J 38185 to 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 and tighten to 5 N·m (44 lb in).



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



12. Install the lower condenser mounting bolts and tighten to 5.4 N·m (48 lb in).



13. Install the upper condenser mounting bolts and tighten to 5.4 N·m (48 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.

Radiator Replacement LH2 Without V92

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure

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 (1).



4. Remove the lower condenser mounting bolts (1).



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

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

6. Remove the transmission oil cooler (TOC) mounting bolts (1).
7. Lower the vehicle.



8. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator outlet hose (2) from the radiator.



9. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator inlet hose (2) from the radiator.



10. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the surge tank inlet hose (2) from the radiator.



11. Remove the radiator support bracket bolts (1).
12. Remove the radiator support brackets (2).
13. Disconnect the upper air baffle retaining pins from the radiator.
14. Remove the radiator.

Installation Procedure

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

Caution: Refer to Fastener Caution in the Preface section.




3. Install the radiator support brackets (2).
4. Install the radiator support bracket bolts (1) and tighten to 9 N·m (80 lb in).



5. Connect the surge tank inlet hose (2) to the radiator. Use J 38185 Hose Clamp Pliers to position the surge tank inlet hose clamp (1) to secure the hose.



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



7. Connect the radiator outlet hose (2) to the radiator. Use J 38185 Hose Clamp Pliers to position the radiator outlet hose clamp (1) to secure the hose.
8. Raise and support the vehicle.



9. Install the TOC mounting bolts (1) and tighten to 5 N·m (44 lb in).
10. Connect the lower retaining pins of the side air baffle to the radiator.



11. Install the lower condenser mounting bolts (1) and tighten to 5.4 N·m (48 lb in).



12. Install the upper condenser mounting bolts (1) and tighten to 5.4 N·m (48 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 LLT

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure

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 (1).



4. Remove the lower condenser mounting bolts (1).



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

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

6. Remove the transmission oil cooler (TOC) mounting bolts (1).
7. Lower the vehicle.



8. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator outlet hose (2) from the radiator.



9. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator inlet hose (2) from the radiator.



10. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the surge tank inlet hose (2) from the radiator.



11. Use J 38185 Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the auxiliary water pump outlet hose (2) from the radiator.



12. Remove the radiator support bracket bolts (1).
13. Remove the radiator support brackets (2).
14. Disconnect the upper air baffle retaining pins from the radiator.
15. Remove the radiator.

Installation Procedure

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

Caution: Refer to Fastener Caution in the Preface section.




3. Install the radiator support brackets (2).
4. Install the radiator support bracket bolts (1) and tighten to 9 N·m (80 lb in).



5. Connect the auxiliary water pump outlet hose to the radiator (2). Use J 38185 Hose Clamp Pliers to position the auxiliary water pump outlet hose clamp (1) to secure the hose.



6. Connect the surge tank inlet hose (2) to the radiator. Use J 38185 Hose Clamp Pliers to position the surge tank inlet hose clamp (1) to secure the hose.



7. Connect the radiator inlet hose (2) to the radiator. Use J 38185 Hose Clamp Pliers to position the radiator inlet hose clamp (1) to secure the hose.



8. Connect the radiator outlet hose (2) to the radiator. Use J 38185 Hose Clamp Pliers to position the radiator outlet hose clamp (1) to secure the hose.
9. Raise and support the vehicle.



10. Install the TOC mounting bolts (1) and tighten to 5 N·m (44 lb in).
11. Connect the lower retaining pins of the side air baffle to the radiator.



12. Install the lower condenser mounting bolts (1) and tighten to 5.4 N·m (48 lb in).



13. Install the upper condenser mounting bolts (1) and tighten to 5.4 N·m (48 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.