Radiator and coolant expansion tank — removal and installation
Warning: Wait until the engine is completely cool before beginning this procedure.
Radiator
Note: The vehicles covered by this manual use spring type radiator hose clamps. If you decide to reuse them, make sure that the hose is installed on a connection that is clean and dry. Don’t try to reuse these clamps on after-market hoses. Replace them with conventional worm drive type clamps.
1. Disconnect the cable from the negative terminal of the battery (see Engine electrical systems).
2. Drain the cooling system (see Tune-up and routine maintenance).
3. Remove the plastic cover over radiator support (see Radiator grille — removal and installation).
4. Remove the cooling fan shroud (see Rocker arms and pushrods — removal, inspection and installation).
5. Disconnect the surge tank hose at the radiator and surge tank.
6. Disconnect and remove the upper radiator hose.
7. Remove the plastic cover over radiator support (see Radiator grille — removal and installation).
4.3L V6, 5.3L and 6.2L V8 models
8. Remove the headlight housings (see Chassis electrical system).
9. Remove the condenser upper mounting bolts and bracket retaining nut (see Oil pan — removal and installation) from the radiator.
10. Remove the upper radiator support (see illustrations).
6.10a Remove the mounting bolts from under the radiator support, on each side …
6.10b … then remove the center bolt (1) and support rod bolts (2) and lift the radiator support up and off
11. Unclip and detach the remove the radiator air baffle (see illustration).
6.11 Unclip each side of the air baffle then lift the baffle off of the radiator
12. Remove the radiator mounting bolts.
13. Depress the condenser retaining tabs and carefully lift the condenser off of the radiator, without disconnecting the condenser lines.
14. Tilt the radiator away from the condenser, then unclip the lower baffle from the bottom of the radiator and remove the radiator out of the engine compartment.
6.0L V8 models
15. Disconnect the transmission cooler lines and engine oil cooler lines from the radiator (see illustrations 5.13 and 5.14), then unclip the lower section of the fan shroud. Lift the shroud around the fan and out of the engine compartment.
16. Remove the radiator mounting bolts and lift the radiator out of the engine compartment.
All models
17. Prior to installation of the radiator, replace any damaged radiator hoses and hose clamps.
18. Radiator installation is the reverse of removal. Tighten the bolts to the torque listed in this Chapter’s Specifications. When installing the radiator, make sure that the radiator seats properly in the lower saddles and that the upper brackets are secure. Install the cooler line retaining clips onto the quick connect fitting before installing the lines, then snap the cooler lines into place on the quick connect fittings. Be sure to reinstall the plastic collars on the quick connect fittings as they lock the retaining clip in place.
19. After installation, refill the cooling system (see Tune-up and routine maintenance), then check the engine oil and automatic transmission fluid levels.
Coolant expansion tank
20. Disconnect the cable from the negative terminal of the battery (see Engine electrical systems).
21. Drain the cooling system as described in Chapter Tune-up and routine maintenance until the expansion tank is empty.
22. Remove the air filter housing (see Fuel and exhaust systems).
23. Detach the coolant hoses from the expansion tank. Unscrew the mounting fasteners, then remove the expansion tank (see illustration).
6.23 Expansion tank mounting details
1 Expansion tank coolant hoses
2 Expansion tank fasteners
24. Prior to installation, make sure the tank is clean and free of debris which could be drawn into the radiator (wash it with soapy water and a brush, if necessary, then rinse thoroughly).
25. Installation is the reverse of removal. Refill the cooling system (see Tune-up and routine maintenance) and check for leaks.