Installing a radiator is one of the most straightforward part replacement a do-it-yourselfer will encounter. On some vehicles, the radiator is very easily accessible while on others, other parts may be in the way. However, the replacement itself is not very difficult. The key is to pay careful attention while removing the old radiator and to perform the same operation in reverse when installing the new one.
On most radiators, there are only four hoses/lines to disconnect: the inlet hose, the outlet hose, and the two trasmission oil cooler lines. Some radiators have a sensor plug on one of the headers which can simply be unscrewed.
Removing the old radiator from the Vehicle.
1. Slowly remove the pressure cap so as to avoid splashing of boiling coolant and save it for later use.
2. Drain the coolant from the system through the drain cock located on the bottom tank of the radiator if your radiator has a draincock, or by removing the bottom radiator hose from the outlet. Make sure to replace the coolant with new 50/50 mix of coolant and distilled water to protect your new radiator.
Be sure to discard used coolant in a safe manner and according to government disposal regulations.
3. If the radiator has a transmission and/or engine oil cooler, use a line wrench to disconnect the lines from the radiator tanks.
Before disconnecting any oil cooler lines, be sure to identify where these lines are connected and mark them so that you can reconnect them properly to your new radiator. Care should be taken to avoid stripping the fittings or kinking the transmission or engine oil cooler lines. To avoid fluid loss, block the ends of the lines after removing them from the radiator fittings.
4. Remove the upper mounting panel and associated sheet metal.
5. Remove the fan shroud or electric fan assembly screws and remove the part, or slide it back away from the radiator far enough to permit removal of the radiator.
6. Disconnect the radiator inlet and outlet hoses, and heater bypass hose (if so equipped) from the radiator hose fittings. Check for brittle or deteriorated hoses. New hoses, clamps and thermostat are strongly recommended. Remove any sensor fittings attached to the radiator tanks, noting the exact location so that proper replacement can be made with the new radiator.
7. Remove the top mounting insulators, or the bolts from the radiator mounting brackets, if so equipped.
Remove the radiator assembly from the vehicle. NOTE: The installation of some high performance replacement radiators may require slight trimming of the rubber mounting insulators to facilitate installation.
Installation of your new radiator
8. Reverse this procedure for the installation of the new radiator.
9. Start to thread transmission or engine oil cooler lines into the cooler fittings carefully. Do this by hand to avoid stripping threads. TIP: It is often better to leave the mounting bolts loose until all the hoses and lines are connected.
Improper installation (cross threading) of the oil cooler lines that result in stripping of the internal threads.
10. Tighten the fittings with a line wrench. Be sure to connect all the lines to their proper location in the radiator tanks and tighten securely. Carefully retighten any connections as required: NOTE: Avoid over-torquing the drain plug; only hand tighten. Do NOT use any tools to tighten the plug as damage to the threads will result.
11. Fill the system with a new 50/50 solution of the proper coolant and deionized or distilled water as recommended by the vehicle manufacturer. Coolant pre-mixes may also be used. Be sure to replace your coolant with the same kind that was removed (refer to your owner's manual to identify the coolant used in your vehicle).
12. Replace the pressure cap. Start engine and check for leaks.
13. After the engine has idled long enough to open the thermostat (engine should reach its normal operating temperature), turn the engine off. Make sure the cooling system has cooled down before slowly removing the pressure cap to check the coolant level: add the 50/50 mix or pre-mix as needed to bring the coolant level to the bottom of the fill neck or to the appropriate level in the overflow tank. Replace the pressure cap. With the engine idling, recheck the automatic transmission fluid level
IMPORTANT
14. Check the coolant recovery reservoir the next few times you drive the vehicle, and, if necessary, add enough coolant mix to bring it up to the proper level.
About the Presenter
Nathan McCullough graduated from Nashville Auto Diesel College in 1998 and received their “Craftsman” Award for maintaining a 3.5 GPA. He holds 7 of the 8 possible automotive repair certifications. Nathan has worked as a technician and service manager for both independent repair facilities and dealerships. He has also worked for Michigan Caterpillar.dkdk
CoolDirect is developing close relationships with radiator shops in different areas of the country for a professional installation of our product.
In the Montreal area
Radiateurs Dorval Ltée.
These instructions are provided for information purposes only. CoolDirect Inc. is not responsible for any problem arising from the use of these instructions and assumes absolutely no responsibility for any and all consequences of the use of these instructions. In following these instructions, you do so at your own risk and assume all related responsibilities. We recommend that you consult a professional for the installation of your radiator.
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