QuestionI need to replace the radiator in my 98 Jeep Grand Cherokee Limited 4.0 4X4. What is the proper procedure? I have never replaced a radiator before!
AnswerI live in Atlanta and I could look at it for u.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REFER TO COOLING SYSTEM DRAINING IN THIS GROUP.
Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) Hose Clamp Tool - Typical SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the tongue of constant tension clamps Clamp Number/Letter Location If replacement is necessary, use only an original equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C condenser for any reason, note the location of all radiator-to-body and radiator-to-A/C condenser rubber air seals Air Seals - Typical These are used at the top, bottom and sides of the radiator and A/C condenser. To prevent overheating, these seals must be installed to their original positions.
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Disconnect the negative battery cable at battery.
Observe the previous WARNINGS and CAUTIONS.
Drain coolant from radiator. Refer to Draining Cooling System in this group.
4.0L Engine: Remove the four fan hub-to-water pump pulley mounting nuts Fan Mounting Nuts - 4.0L 6-Cyl. Engine Carefully remove the fan assembly from the water pump pulley and position to center of fan shroud. Fan belt removal is not necessary as the water pump studs will hold the pump pulley in position.
Do not remove fan/viscous fan drive assembly from vehicle at this time..
5.2/5.9L Engines: The thermal viscous fan drive is attached (threaded) to the water pump hub shaft Fan Blade and Viscous Fan Drive - 5.2/5.9L V-8 Engines Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts Fan Blade and Viscous Fan Drive - 5.2/5.9L V-8 Engines to prevent pulley from rotating. Drive belt removal is not necessary for removal of fan drive.
Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time..
Remove the two fan shroud-to-upper radiator crossmember mounting nuts Radiator and A/C Condenser Mounting .
Remove the fan assembly and fan shroud (as one unit) from vehicle.
Special quick-connect fittings are used to join the transmission cooling lines to the radiator. Removal procedures are different between the 4.0L and 5.2/5.9L engines. Disconnect the cooling lines from the radiator. Refer tofor transmission cooling line removal and installation.
The radiator upper crossmember Radiator Upper Crossmember - Typical can be adjusted left or right through the use of slotted holes. Before removal, mark the original position of the crossmember..
Eight clips are used to retain a rubber seal Radiator Upper Crossmember - Typical to the body and upper radiator crossmember. Gently pry up the outboard clips (two per side) until rubber seal can be removed. Do not remove the clips entirely. Fold back the seal on both sides for access to (the hidden) grille opening reinforcement mounting bolts Radiator Upper Crossmember - Typical Remove these two bolts.
Remove the grill. Refer to Body.
Remove the upper brace bolt from each of the two radiator braces Radiator and A/C Condenser Mounting
Remove the two crossmember-to-radiator mounting nuts Radiator Upper Crossmember - Typical
Working through grill opening, remove the lower bracket bolt securing lower part of hood latch support bracket to lower frame crossmember Radiator and A/C Condenser Mounting
Remove the remaining four bolts securing the radiator upper crossmember to the body. Do not remove the hood latch or hood latch cable from the crossmember. Lift the crossmember straight up and lay to the side.
Equipped with air conditioning: Remove the two A/C condenser-to-radiator mounting bolts Radiator and A/C Condenser Mounting These two bolts are also used to retain the side mounted rubber air seals Air Seals - Typical These seals are compressed between the A/C condenser and the radiator. The lower part of the air seals are compressed between the radiator and the A/C condenser mounting brackets Radiator Alignment Dowels
Not equipped with air conditioning: Remove the two bolts retaining the side mounted rubber air seals Air Seals - Typical to the radiator. The lower part of the air seals are compressed between the radiator and the radiator lower crossmember
CAUTION: Note the location of all rubber air seals Air Seals - Typical To prevent overheating, they must be installed back to their original positions.
Disconnect the coolant reserve/overflow tank hose Radiator Upper Crossmember - Typical at radiator.
Remove upper radiator hose at radiator. A special clamp tool Hose Clamp Tool - Typical must be used to remove the constant tension hose clamps.
4.0L Engine Only: Remove the lower radiator hose at the water pump end.
To gain access to lower radiator hose clamp at radiator, gently lift the radiator a slight amount. Remove hose clamp and hose.
The lower part of radiator is equipped with two alignment dowel pins Radiator and A/C Condenser Mounting Radiator Alignment Dowels They are located on the bottom of radiator tank and fit into rubber grommets. These rubber grommets are pressed into the radiator lower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF EQUIPPED) IS UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF. REFER TO REFRIGERANT WARNINGS IN GROUP 24, HEATING AND AIR CONDITIONING BEFORE HANDLING ANY AIR CONDITIONING COMPONENT.
If equipped with an auxiliary automatic transmission oil cooler, use caution when removing radiator. The oil cooler lines are routed through a rubber air seal on the left side of radiator. Do not cut or tear this seal.
Gently lift up and remove radiator from vehicle. Be careful not to scrape the radiator fins against any other component. Also be careful not to disturb the air conditioning condenser (if equipped)
INSTALLATION
CAUTION: Before installing the radiator or A/C condenser, be sure the radiator-to-body and radiator-to-A/C condenser rubber air seals Air Seals - Typical are properly fastened to their original positions. These are used at the top, bottom and sides of the radiator and A/C condenser. To prevent overheating, these seals must be installed to their original positions.
Equipped with air conditioning: Gently lower the radiator into the vehicle. Guide the two radiator alignment dowels through the holes in the rubber air seals first and then through the A/C support brackets Radiator Alignment Dowels Continue to guide the alignment dowels into the rubber grommets located in lower radiator crossmember Radiator Alignment Dowels The holes in the L-shaped brackets (located on bottom of A/C condenser) must be positioned between bottom of rubber air seals and top of rubber grommets.
Not equipped with air conditioning: Gently lower the radiator into the vehicle. Guide the two radiator alignment dowels through the holes in the rubber air seals. Continue to guide the alignment dowels into the rubber grommets located in lower radiator crossmember.
Connect the lower radiator hose and hose clamp to radiator
CAUTION: The tangs on the hose clamp must be positioned straight down.
4.0L Engine: Connect the lower radiator hose at the water pump.
Connect the upper radiator hose at the radiator.
Equipped with air conditioning: Install the two A/C condenser- to-radiator mounting bolts Radiator and A/C Condenser Mounting These two bolts are also used to retain the rubber air seal Air Seals - Typical to the sides of radiator.
Not equipped with A/C: Install the two bolts retaining the rubber air seal Air Seals - Typical to sides of radiator.
Install coolant reserve/overflow tank hose at radiator.
If radiator-to-upper crossmember rubber isolators were removed from radiator, install them. Tighten mounting nuts to 3 N·m (24-36 in. lbs.) torque. Position upper radiator crossmember to radiator.
Working through grill opening, install and tighten the hood latch support bracket-to-lower frame crossmember bolt Radiator and A/C Condenser Mounting
Install the four bolts securing the radiator upper crossmember to the body Radiator Upper Crossmember - Typical
Install two nuts securing the radiator to the upper radiator crossmember Radiator Upper Crossmember - Typical Tighten nuts to 2 N·m (18-21 in. lbs.) torque.
Install the upper bolt to each radiator brace Radiator and A/C Condenser Mounting
Install the grill. Refer to Body.
Install the rubber seal Radiator Upper Crossmember - Typical to the four (outer) seal mounting clips on vehicle body. Press down on clips until seated.
Install the transmission cooler lines to radiator. Refer tofor installation.
Position the fan assembly and fan shroud (as one unit) to the vehicle.
Position fan shroud to radiator. Be sure the alignment tabs at the lower part of shroud are placed into the slots near lower part of radiator.
Be sure the upper and lower portions of the fan shroud are firmly connected. All air must flow through the radiator.
Install the two nuts securing the fan shroud to the upper radiator crossmember Radiator and A/C Condenser Mounting
4.0L Engine: Install the four nuts securing the fan assembly to the water pump Fan Mounting Nuts - 4.0L 6-Cyl. Engine Tighten nuts to 27 N·m (20 ft. lbs.) torque.
5.2/5.9L Engines: Install the fan/viscous fan drive assembly to the water pump.
Rotate the fan blades (by hand) and check for interference at fan shroud.
Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud.
Fill cooling system. Refer to Refilling Cooling System in this group.
Connect battery cable at battery.
Start and warm engine. Check for leaks.
