Radiator: Service and Repair

Removal Procedure

^ Tools Required
- J37097-A Hose Clamp Remover/Installer
- J38185 Hose Clamp Pliers

1. Remove the cooling fans. Refer to Cooling Fan Motor Replacement - Electric.





2. Position the J37097-A to the clamp in order to remove the outlet radiator hose from the radiator.
3. Disconnect the lower transaxle oil cooler line from the radiator.





4. Disconnect the lower engine oil cooler line from the radiator.





5. Position the J38185 (3) to the clamp in order to remove the generator cooler inlet hose (2) from the radiator (1).





6. Remove the two condenser mounting bolts.

Important: Care should be taken when removing the condenser not to damage the lower attachment points of both the radiator and condenser.





7. Lift the condenser upward slightly in order to release the lower feet from the lower mounting features located at the front of the radiator.
8. Lift the radiator up and out the vehicle.

Installation Procedure





1. Install the radiator insulators (1) to the frame.
2. Position the radiator alignment dowels (2) to align with the insulators (1).

Important: Care should be taken when Installing the condenser not to damage the lower attachment points of both the radiator and condenser.





3. Position the condenser, aligning the lower feet to the lower mounting features located at the front of the radiator.

Notice: Refer to Fastener Notice in Service Precautions.

Important: The bolts retaining the condenser to the radiator end tanks are a special length and should be the ONLY bolts used upon reinstallation. The use of longer bolts will damage the radiator end tanks.





4. Install the condenser mounting bolts.
Tighten the condenser mounting bolts to 13 Nm (115 inch lbs.).





5. Position the J38185 (3) to the clamp in order to connect the generator cooler inlet hose (2) to the radiator (1).





6. Connect the lower engine oil cooler line to the radiator.
Tighten the engine oil cooler line to 18 Nm (13 ft. lbs.).





7. Connect the lower transaxle oil cooler line to the radiator.

Important: Ensure the transaxle oil cooler line is positioned upwards while tightening.

Tighten the transaxle oil cooler line to 35 Nm (26 ft. lbs.).





8. Position the J37097-A to the clamp in order to connect the outlet radiator hose to the radiator.
9. Install the cooling fans. Refer to Cooling Fan Motor Replacement - Electric.