Radiator Replacement
Radiator Replacement
Special Tools
J 41623-B - Quick Connect Release Tool
Removal Procedure
Warning: Refer to Battery Disconnect Warning Battery Disconnect Warning.
1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
Warning: Refer to Radiator Cap Removal Warning Service Precautions.
2. Ensure engine is below 50 C before removing the coolant pressure cap.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning: Refer to Safety Glasses Warning Safety Glasses Warning.
3. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
4. If needed, place a suitable container beneath the radiator and engine.
5. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
6. Remove the air deflector. Refer to Front Air Deflector Replacement .
7. Detach the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (V8) Radiator Outlet Hose Replacement (V8).
8. Lower the vehicle.
9. Remove the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
10. Remove the mass air flow meter. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Service and Repair.
11. Detach the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.
12. Where fitted, detach the coolant recovery reservoir hose (1) from the coolant pressure cap (2).
13. Remove the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement Engine Coolant Air Bleed Hose Replacement.
Note: When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.
14. Using the cooler J 41623-B - quick connect release tool disconnect the transmission cooler lines (2) from the flexible hoses (1).
* Detach plastic cover from hose fitting and slide along pipe.
* Open the cooler J 41623-B - quick connect release tool then close and clip around the hose to be disconnected.
* While holding the flexible hoses (1) push the hoses inwards with one hand, then pull back to separate from the steel transmission cooler lines (2).
* Repeat procedure for the second fitting.
15. Remove the radiator support brackets (2) from top of radiator by raising the securing lock (3) 10mm and then sliding the bracket off the radiator slide pin (1). Carry out same procedure for other bracket.
16. Disconnect the cooling fans electrical connector (2) from the main wiring loom connector (1).
17. Remove the two radiator and condenser retaining bolts (1).
Note: When manoeuvring the condenser take care not to fracture the A/C lines.
18. Detach the condenser by lifting it out of the retaining brackets (1) located on the radiator assembly.
19. Remove the radiator and fan assembly, by tilting it forward and lifting it out of the rubber grommets located in the cross member.
Installation Procedure
1. Install the radiator into the rubber retaining grommets located in the cross member.
2. Install the condenser into the radiator.
Caution: Refer to Fastener Caution Fastener Caution.
3. Install the two radiator and condenser retaining bolts (1) and tighten to 11 Nm (97 lb in).
4. Connect the cooling fans electrical connector (2) to the main wiring loom connector (1).
5. Install the radiator retaining brackets (2), onto the radiator slide pin (1).
6. Secure the retaining brackets by pushing the securing lock (3) downwards until lock reaches bottom of radiator bracket.
Note: Ensure cloth is removed before carrying out installation procedure.
7. Connect the flexible hoses (1) to the transmission cooler lines (2), listen for an audible click to confirm fitting.
8. Push plastic cover forward along pipe and clip onto hose fitting.
9. Install the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement Engine Coolant Air Bleed Hose Replacement.
10. Where fitted, install the coolant recovery reservoir hose (1) to the coolant pressure cap (2).
11. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.
12. Install the mass air flow meter. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Service and Repair.
13. Install the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning: Refer to Safety Glasses Warning Safety Glasses Warning.
14. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
15. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (V8) Radiator Outlet Hose Replacement (V8).
16. Install the air deflector. Refer to Front Air Deflector Replacement .
17. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
18. Lower the vehicle.
19. Install the battery ground lead to the vehicle. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
20. Inspect cooling system for leaks.