Radiator: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN ENGINE COOLANT
3. DISCONNECT RADIATOR RESERVOIR HOSE FROM RADIATOR
4. DISCONNECT RADIATOR UPPER HOSE FROM RADIATOR
5. DISCONNECT RADIATOR LOWER HOSE FROM RADIATOR
6. DISCONNECT A/T OIL COOLER HOSES FROM RADIATOR
7. REMOVE RADIATOR RESERVOIR TAN

8. REMOVE RADIATOR ASSEMBLY
a. Disconnect the A/T oil cooler hoses from the clamp on the fan- shroud. Loosen the fan pulley mounting nuts holding the fluid coupling to the fan bracket.
Remove generator drive belt.
Remove the 3 bolts holding the fan shroud to the radiator.
e. Remove the 4 fan pulley mounting bolts.
f. Pull out the fan with fluid coupling, fan pulley and fan shroud.

g. Remove the 2 nuts.

h. Remove the 4 nuts, 2 bolts and 2 radiator brackets.
i. Lift out the radiator assembly.

9. REMOVE RADIATOR SIDE SUPPORTS FROM RADIATOR
Remove the 8 nuts and 2 radiator supports.

INSTALLATION

1. INSTALL SIDE SUPPORTS TO RADIATOR
Install the 2 side supports with the 8 nuts.

Torque: 12.7 Nm (9 inch lbs.)

2. INSTALL RADIATOR ASSEMBLY
a. Place the radiator assembly to the body.

b. Temporarily install the 2 nuts.

c. Install the radiator brackets to the radiator assembly and body.

Torque:
Bolt: 18 Nm (13 ft. lbs.)
Nut: 20 Nm (15 ft. lbs.)

d. Tighten 2 nuts.

Torque: 20 Nm (15 ft. lbs.)

3. INSTALL FAN PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND GENERATOR DRIVE BELT
a. Place the fan with fluid coupling, fan pulley and fan shroud in position.
b. Temporarily install the fan mounting nuts.
c. Install fan shroud with the 3 bolts.

Torque: 5.0 Nm (43 inch lbs.)

d. Connect the A/T oil cooler hoses to the clamp on the fan shroud.
e. Install the generator drive belt.
f. Tighten the 4 fan pulley mounting nuts.
4. INSTALL RADIATOR RESERVOIR TANK
5. CONNECT A/T OIL COOLER HOSES TO RADIATOR
6. CONNECT RADIATOR UPPER HOSE TO RADIATOR
7. CONNECT RADIATOR LOWER HOSE TO RADIATOR
8. CONNECT RADIATOR RESERVOIR HOSE TO RADIATOR
9. FILL WITH ENGINE COOLANT
10. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
11. RECHECK ENGINE COOLANT LEVEL
12. INSTALL ENGINE UNDER COVER NO.1