REMOVAL & INSTALLATION

CAUTION
Always perform this work on a completely cool engine. The coolant will retain heat and pressure for several hours after use. Never remove the radiator cap or hoses if the radiator feels hot or warm to the touch. Liquid under pressure can turn to steam instantly when released; severe scalding can result. Before beginning any work, make certain the ignition is OFF.

4-Cylinder Engines

NOTE: On some models the battery and shroud(s) may have to be removed for additional working access.

1. Disconnect the negative battery cable. Set the heater temperature control to HOT inside the truck.
2. Using a large capacity container, loosen the radiator drain plug and drain the cooling system. It will drain quicker with the radiator cap removed.

   CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

3. Disconnect the upper and lower hoses at the radiator and disconnect the overflow hose to the reserve tank.
4. If equipped with an automatic transmission, disconnect the oil cooler lines at the radiator and at the transmission. Be prepared to contain oil spillage. Remove the hose assembly from the truck; plug the transmission ports and hose ends quickly to keep oil in and dirt out.
5. Remove the radiator mounting bolts and lift out the radiator.

   To install:

6. Position the radiator in the truck, making certain all the mounts and bushings are correctly installed. Tighten the mounting bolts enough to hold well but do not overtighten them. Double check the draincock to make sure it is closed.
7. Reassemble the automatic transmission oil cooler lines and install the retaining bracket. Make certain the hoses are properly routed and firmly attached at both ends.
8. Connect the upper and lower radiator hoses and the overflow hose. Check each fitting and the inside of the hose for any corrosion or debris which would prevent a good seal.
9. Fill the system with coolant.
10. Start the engine and allow it to idle with the radiator cap removed. When the engine has warmed enough, the thermostat will open and water flow will be visible within the radiator. Fill the coolant to the bottom of the radiator neck and install the cap.

    CAUTION
    Do not lean over the radiator neck while the engine is running. Hot coolant may be splashed out by air trapped within the system. Keep hands, tools and clothing away from the fans which may engage at any time as the coolant heats up.

11. Shut the engine off and check the hose connections carefully for leaks. With the engine fully warm, a small leak may be emitting steam rather than liquid. If any leaks are found, allow the engine to cool completely before attempting repairs.

    Fig. 1: Radiator assembly — 2.0L, 2.3L Diesel and 2.6L Engines

    Fig. 2: Radiator assembly — 2.4L and 3.0L (12 Valve) Engines

6-Cylinder Engines

CAUTION
If vehicle if equipped with SRS airbag system refer to Section 6 for the system precautions. Be extremely careful not to subject the front impact sensor to any shocks during removal and installation of the radiator assembly. The SRS system can be extremely dangerous; heed all system cautions.

1. Set the heater temperature control to HOT inside the vehicle.
2. Disconnect and remove the battery.

   Fig. 3: Radiator assembly — 3.0L (24 Valve) and 3.5L Engines

3. Using a large capacity container, loosen the radiator drain plug and drain the cooling system. It will drain quicker with the radiator cap removed.

   CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

4. Disconnect the upper and lower hoses and disconnect the overflow hose to the reserve tank.
5. Remove the upper fan shroud, then the lower fan shroud for the 3.0L (12 valve) engines. For the 3.0L (24 valve) and 3.5L engines, the fan shroud is one piece.
6. Disconnect the automatic transmission cooler lines.
7. Remove the radiator retaining bolts and remove the radiator.

   To install:

8. Reinstall the radiator in position, making certain all the mounts and bushings are correctly installed. Tighten the mounting bolts enough to hold well but do not overtighten them. Double check the draincock to make sure it is closed.
9. Connect the automatic transmission cooler lines.
10. Install the lower shroud first, then the upper shroud.
11. Connect the upper and lower radiator hoses and the overflow hose. Check the each fitting and the inside of the hose for any corrosion or debris which would prevent a good seal.
12. Install the battery and connect the terminals.
13. Fill the system with coolant. Start the engine and allow it to idle with the radiator cap removed. When the engine has warmed enough, the thermostat will open and water flow will be visible within the radiator. Fill the coolant to the bottom of the radiator neck and install the cap.

    CAUTION
    Do not lean over the radiator neck while the engine is running. Hot coolant may be splashed out by air trapped within the system. Keep hands, tools and clothing away from the fan.

14. Shut the engine off and check the hose connections carefully for leaks. With the engine fully warm, a small leak may be emitting steam rather than liquid. If any leaks are found, allow the engine to cool completely before attempting repairs.