How to install a radiator in a Jeep Wrangler TJ. Direct Fit?

Radiator Removal and Installation

1. Disconnect negative battery cable at battery.
2. Remove the radiator cap.
3. Remove the condenser lower seal from the lower core support .
4. Drain cooling system drain coolant into a clean container for reuse.
5. Remove radiator upper and lower hose clamps Remove radiator hoses.
6. Disconnect coolant reserve/overflow tank hose from radiator.
7. 2.4L ONLY – Remove the electric cooling fan.
8. 4.0L ONLY – Remove the reservoir tank and power steering reservoir and position out of the way.
9. 4.0L ONLY – Remove the four fan shroud mounting bolts . Position the fan shroud back over the fan blades.
10. If equipped, disconnect and plug automatic transmission fluid cooler lines.
11. Remove six radiator mounting bolts. Position the front axle vent hose to the side.
12. The lower part of radiator is equipped with two alignment dowel pins . They are located on the bottom of radiator tank and fit into rubber grommets. These rubber grommets are pressed into the radiator lower crossmember.
13. Lift radiator straight up and out of vehicle taking care not to damage radiator fins.
14. When removing radiator, note position of the rubber seals located on the top and bottom of radiator (on certain models only) . To prevent possible overheating, these seals must be installed to their original positions

To install:

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. Guide the two radiator alignment dowels into the rubber grommets located in lower radiator cross member. Install and tighten the six mounting bolts to 72 inch lbs. (8 Nm) torque.
2. Close radiator drain cock.
3. 2.4L ONLY – Install the electric cooling fan.
4. Position fan shroud and power steering reservoir tank (if equipped). Install and tighten four mounting bolts to 72 inch lbs. (8 Nm) torque.
5. If equipped, remove plugs and connect automatic transmission fluid cooler lines and constant tension clamps CAUTION The tangs on the hose clamps must be positioned straight down.
6. Connect radiator hoses and install hose clamps.
7. Position and install the condenser lower seal .
8. Connect battery negative cable.
9. Fill cooling system with correct coolant.
10. Connect coolant recovery bottle hose.
11. Install radiator cap.
12. Check and adjust automatic transmission fluid level (if equipped).
13. Start engine and check for leaks

COOLANT DRAIN, FLUSH & REFILL

Warning: Do not remove the cylinder block drain plugs or loosen the radiator draincock with system hot and under pressure. Serious burns from coolant can occur.
Caution: The cooling system normally operates at 14-16 psi pressure. Exceeding this pressure may damage the radiator or hoses.
Radiator draincock is located on the righthand/lower side of radiator facing to rear of vehicle.

1. With engine cold, raise vehicle on a hoist and locate radiator draincock.
2. Attach one end of a hose to draincock. Put other end into a clean container.
3. Open draincock and drain coolant from radiator. This will empty coolant reserve/overflow tank.
4. When tank is empty, remove radiator cap and continue draining cooling system.
5. Disconnect radiator hoses from radiator fittings.
6. Attach a section of radiator hose to the radiator bottom outlet fitting and insert flushing.
7. Connect a water supply hose and air supply hose to flushing gun.
8. Allow radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to fill between blasts.
9. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages.
10. Remove thermostat housing and thermostat.
11. Install thermostat housing.
12. Disconnect radiator upper hose from radiator and attach flushing gun to hose.
13. Disconnect radiator lower hose from water pump. Attach a lead away hose to water pump inlet fitting.
14. Connect water supply hose and air supply hose to the flushing gun. Allow engine to fill with water.
15. When engine is filled, apply air in short blasts, allowing system to fill between air blasts.
16. Continue until clean water flows through the lead away hose.
17. Remove lead away hose, flushing gun, water supply hose and air supply hose.
18. Remove thermostat housing.
19. Install thermostat and housing with a replacement gasket.
20. Connect radiator hoses.
21. Tighten radiator draincock and cylinder block drain plug(s) (if removed).
22. Remove cooling system bleed plug from radiator upper hose inlet housing.
23. Fill cooling system with antifreeze mixture until coolant begins coming out of cooling system bleed hole.
24. Fill radiator to top and install radiator cap.
25. Add sufficient coolant to reserve/overflow tank to raise level to FULL mark.
26. With heater control unit in HEAT position, operate engine with radiator cap in place.
27. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into radiator from reserve/overflow tank.
28. Add coolant to reserve/overflow tank as required.
29. Repeat steps 22 through 27 three times.
30. Add required coolant to raise tank level to FULL mark after each cool down period.