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Radiator

Engine, Cooling and Exhaust › Cooling System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartRadiator
ManufacturerCHY
OEM part #68033227AA
Price$202.00

Labor

Replace1.8 hr
Warranty 0.0 hrSkill B
With Auto Trans, Add0.2 hr
Warranty 0.0 hrSkill B
Procedures
Engine Cooling Radiator - Removal12 steps
⚠ 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.
△ 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. 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.
⚠ WARNING
The air conditioning system (if equipped) is under a constant pressure even with the engine off. Refer to refrigerant warnings in, heating and air conditioning before handling any air conditioning component.
ℹ NOTE
The radiator and radiator cooling fan can be removed as an assembly. It is not necessary to remove the cooling fan before removing or installing the radiator.
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  1. Disconnect the negative battery cable.
  2. Drain coolant from radiator Service and Repair.
  3. KA and KK vehicles, remove combination coolant recovery/washer fluid reservoir assembly.Coolant Recovery Bottle - Removal
  4. Remove the front grille Grille - Removal.
  5. Remove the viscous cooling fan from the engine (if equipped).Electric Radiator Fan - Removal
  6. Remove the two radiator mounting bolts.
  7. Disconnect the connector for the electric cooling fan.
  8. Disconnect the power steering cooler line from cooler.
  9. Disconnect the radiator upper and lower hoses.
  10. Disconnect the overflow hose from radiator (2).
  11. The lower part of radiator is equipped with two alignment dowel pins (2). They are located on the bottom of radiator tank and fit into rubber grommets (3). These rubber grommets (3) are pressed into the radiator lower crossmember (4).
  12. Gently lift up and remove radiator (1) 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).
Engine Cooling Radiator - Installation12 steps
△ CAUTION
Before installing the radiator or A/C condenser, be sure the radiator-to-body and radiator-to-A/C condenser rubber air seals 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.
△ CAUTION
The tangs on the hose clamps must be positioned straight down.
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  1. Gently lower the radiator (1) and fan shroud into the vehicle. Guide the two radiator alignment dowels (2) into the rubber grommets (3) located in lower radiator crossmember (4).
  2. Connect the radiator upper and lower hoses and hose clamps to radiator.
  3. Install both radiator mounting bolts.
  4. Reconnect the electric cooling fan connector.
  5. Install the grille Grille - Installation.
  6. Reinstall the viscous cooling fan to the engine (if equipped).Electric Radiator Fan - Installation
  7. Rotate the fan blades (by hand) and check for interference at fan shroud.
  8. KA and KK vehicles, install the combination coolant recovery/washer fluid reservoir assembly.Coolant Recovery Bottle - Installation
  9. Install coolant reserve/overflow tank hose at radiator.
  10. Refill cooling system Service and Repair.
  11. Connect negative battery cable.
  12. Start and warm engine. Check for leaks.Component Tests and General Diagnostics
Radiator: Description and Operationreference
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DESCRIPTION All vehicles are equipped with a cross flow type radiator (1) with plastic side tanks. Plastic tanks, while stronger than brass, are subject to damage by impact, such as from tools or wrenches. Handle radiator with care.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fittings. Attach a section of radiator hose to the radiator bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.
CAUTION: The cooling system normally operates at 97-110 kPa (14 -16 psi) pressure. Exceeding this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. For more information, refer to operating instructions supplied with flushing equipment. Have radiator cleaned more extensively by a radiator repair shop.
RADIATOR📷 6

Description

1 - RADIATOR
All vehicles are equipped with a cross flow type radiator (1) with plastic side tanks.
Plastic tanks, while stronger than brass, are subject to damage by impact, such as from tools or wrenches. Handle radiator with care.

Removal

1 - AIR DAM 2 - RADIATOR 3 - AIR DAM 4 - A/C CONDENSER 5 - AIR SEAL
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.
Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
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. 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.
1
Disconnect the negative battery cable at battery.
2
Drain coolant from radiator. See STANDARD PROCEDURE.
3
Remove the front grille. Refer to REMOVAL .
4
Remove the cooling fan from the engine, if equipped.
5
Remove the two radiator mounting bolts.
6
Disconnect the connector for the electric fan.
7
Disconnect the power steering cooler line from cooler.
8
Disconnect the radiator upper and lower hoses.
9
Disconnect the overflow hose from radiator (2).
1 - RADIATOR 2 - ALIGNMENT DOWEL 3 - RADIATOR LOWER ISOLATOR 4 - RADIATOR LOWER CROSSMEMBER
10
The lower part of radiator is equipped with two alignment dowel pins (2). 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, heating and air conditioning before handling any air conditioning component.
NOTE
The radiator and radiator cooling fan can be removed as an assembly. It is not necessary to remove the cooling fan before removing or installing the radiator.
11
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).

Cleaning

Clean radiator fins With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.

Inspection

The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.

Installation

1 - AIR DAM 2 - RADIATOR 3 - AIR DAM 4 - A/C CONDENSER 5 - AIR SEAL
CAUTION: Before installing the radiator or A/C condenser, be sure the radiator-to- body and radiator-to-A/C condenser rubber air seals 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.
1 - RADIATOR 2 - ALIGNMENT DOWEL 3 - RADIATOR LOWER ISOLATOR 4 - RADIATOR LOWER CROSSMEMBER
1
Gently lower the radiator and fan shroud into the vehicle. Guide the two radiator alignment dowels into
the rubber grommets located in lower radiator crossmember.
2
Connect the radiator upper and lower hoses and hose clamps to radiator.
CAUTION
The tangs on the hose clamps must be positioned straight down.
3
Install coolant reserve/overflow tank hose at radiator.
4
Install both radiator mounting bolts.
5
Reconnect the electric cooling fan.
6
Install the grille. Refer to INSTALLATION .
7
Reinstall the cooling fan to the engine.
8
Rotate the fan blades (by hand) and check for interference at fan shroud.
9
Refill cooling system. See STANDARD PROCEDURE.
10
Connect battery cable at battery.
11
Start and warm engine. Check for leaks.
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