Removal, Installation & Coolant Refill Information
REMOVAL PROCEDURENOTE: Before replacing any parts, remove the new front transverse filler assembly from the Hot Weather Kit and have it painted the same body color of the vehicle to be repaired. Use a chip resistant type paint.
1. Record the preset radio stations and then disconnect the battery ground cable.
2. Loosen the radiator drain plug and drain the coolant from the radiator.
3. Remove the radiator grille.
FIGURE 1:
4. Remove the front parking lamps. They are spring mounted.
5. Remove the old front transverse filler assembly from the vehicle and discard (Figure 1).
FIGURE 2:
6. Disconnect the fan motor harness connector (Figure 2).
7. Remove the upper and lower radiator hoses from the engine Figure 2). Save the hose clamps. Remove the radiator overflow tube from the radiator.
FIGURE 3:
8. Loosen the tapered plug on the right rear corner of the engine block (Figure 3). This plug is located below the water pipe toward the front of the vehicle. Allow the coolant to drain out of the block. After draining, install the plug and torque it to 25-32 ft.lb.
FIGURE 4:
9. Remove the radiator reserve tank (Figure 4).
10. Empty the coolont out of the reserve tank and then reinstall the reserve tank.
FIGURE 5:
11. Disconnect the A/T oil cooler hoses from the radiator (Figure 5).
12. Remove and discard the 4 radiator mounting bolts.
13. Remove the radiator and fan/motor assembly from the vehicle.
FIGURE 6:
14. Remove the fan/motor assembly from the radiator. The 4 bolts/nuts will be reused when installing the new fan/motor assembly (Figure 6).
INSTALLATION PROCEDURES
15. Install the new thermo switch to the new radiator.
16. Install the new fan/motor assembly to the new radiator using the 4 bolts/nuts removed in step 14.
FIGURE 7:
17. Install the new radiator into the vehicle using the 4 new mounting bolts. Install the long bolt at the top right hole (Figure 7). Connect the thermo switch connector and fan motor connector.
18. Connect the A/T oil cooler hoses to the new radiator.
19. Install the new upper and lower radiator hoses. Use the 1 new clamp on the upper hose at the radiator (Figure 7) and reuse the 3 old clamps removed in step 7. Torque clamps to 26-35 in.lb.
FIGURE 8:
NOTE: The white point on the radiator upper hose should be aligned with the location lug on the engine outlet fitting. The white point on the radiator lower hose should be aligned with the location lug on the radiator inlet pipe lower side (Figure 8).
20. Carefully install the newly painted front filler assembly.
21. Install the parking lamps and radiator grille.
FIGURE 9:
22. Install the air guide to the top edge of the grille assembly using the 4 new clips provided. Fasten the rear edge of the air guide with existing screws at the locations shown in Figure 9.
FIGURE 10:
23. Install the new air deflector to the top of the radiator using the new bolt and screws provided (Figure 10).
24. Connect the battery ground cable and set the radio stations as noted in step 1. Reset the clock to the current time.
COOLANT REFILL PROCEDURE
25. Fill the radiator and reserve tank with clean recommended coolant mixture.
Recommended Coolant
ANTI-FREEZE MIXTURE RATIO
(Anti-freeze/Water)
Texaco JC-86 or BASF 340-2 30-60%
CAUTION: Only TEXACO JC-86 or BASF 340-2 anfi-freeze coolant should be used in the new aluminum radiator. Radiator damage may result if any other coolant is used.
26. Run the engine until the coolant has warmed up enough so that the thermostat valve opens. Then stop the engine.
27. Remove the radiator cap and add the coolant mixture until it reaches the filler neck.
28. Make sure that there is no leakage from the radiator or hose connections.