Radiator Replacement Diesel

Special Tools

J 38185 Hose Clamp Pliers

Note: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
2. Remove the upper radiator baffle.
3. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
4. Remove battery. Refer to Battery Replacement.
5. Remove the charged air cooler inlet hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement.



6. Remove the clamp at the radiator inlet using the J 38185 .
7. Remove the radiator inlet hose (5) from the radiator.
8. Remove the outlet heater hose clamp at the radiator using the J 38185 .
9. Remove the outlet heater hose (2) from the radiator.
10. Remove the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.
11. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.
12. Remove the engine oil fill tube. Refer to Oil Filler Tube Replacement.
13. Remove intake manifold tube. Refer to Intake Manifold Tube Replacement.



14. Remove the upper radiator baffle.

Remove the fan shroud bolts (1) from the top of the radiator support.

15. Remove the fan shroud bolts (3) from the sides of the fan shroud.



16. Remove the radiator mounting bolts from the charged air cooler.
17. Remove the charge air cooler bolts to core support.
18. Remove the radiator and charge air cooler as assembly.
19. Remove radiator bolts to charge air cooler.
20. Remove the radiator insulators.
21. Inspect the following components:

•	The radiator

•	The insulators

•	The hoses and clamps

•	The mounting hardware

•	Replace the components as necessary.

1. Install the radiator insulators.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the radiator to the charge air cooler and tighten the bolts to 6 N·m (53 lb in).
3. Install the radiator and charge air cooler as an assembly.
4. Install the radiator mounting bolts to the charged air cooler and tighten to 6 N·m (53 lb in).



5. Install the fan shroud bolts (1) to the top of the radiator support and tighten to 6 N·m (53 lb in).
6. Install the fan shroud bolts (3) to the sides of the fan shroud and tighten to 6 N·m (53 lb in).
7. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.
8. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.



9. Install the radiator inlet hose (5) to the radiator.
10. Install the hose clamp at the radiator inlet housing using the J 38185 .
11. Install the outlet heater hose (2).
12. Install the outlet heater hose clamp using the J 39529 .
13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement.
14. Install oil fill tube. Oil Filler Tube Replacement.
15. Install the upper radiator baffle.
16. Install the battery. Refer to Battery Replacement.
17. Install the charged air cooler hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement.
18. Install the surge tank assembly. Refer to Radiator Surge Tank Replacement.
19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.



20. Install the upper radiator baffle.
21. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities.
22. Inspect the engine oil level. Refer to Approximate Fluid Capacities.

Radiator Replacement Gas

Special Tools

J 38185 Hose Clamp Pliers

Note: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or Air Cleaner Assembly Replacement for the 4.3L engine.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.



3. Remove the clamp at the radiator inlet using the J 38185 .
4. Remove the radiator inlet hose (5) from the radiator.
5. Remove the outlet heater hose clamp at the radiator using the J 38185 .
6. Remove the outlet heater hose (2) from the radiator.
7. Remove the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmission.
8. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.



9. Remove the fan shroud bolts (1) from the top of the radiator support.
10. Remove the fan shroud bolts (3) from the sides of the fan shroud.



11. Remove the radiator (2).
12. Remove the radiator insulators (1, 3).
13. Inspect the following components:

•	The radiator

•	The insulators

•	The hoses and clamps

•	The mounting hardware

•	Replace the components as necessary.

1. Install the radiator insulators (1, 3).
2. Install the radiator (2).

Caution: Refer to Fastener Caution in the Preface section.




3. Install the fan shroud bolts (1) to the top of the radiator support and tighten to 6 N·m (53 lb in).
4. Install the fan shroud bolts (3) to the sides of the fan shroud and tighten to 6 N·m (53 lb in).
5. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.
6. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmission.



7. Install the radiator inlet hose (5) to the radiator.
8. Install the hose clamp at the radiator inlet housing using the J 38185 .
9. Install the outlet heater hose (2).
10. Install the outlet heater hose clamp using the J 39529 .
11. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or Air Cleaner Assembly Replacement for the 4.3L engine.
13. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities.
14. Inspect the engine oil level. Refer to Approximate Fluid Capacities.