{"id":80512,"date":"2023-09-13T06:33:42","date_gmt":"2023-09-13T13:33:42","guid":{"rendered":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/?p=80512"},"modified":"2024-02-10T16:27:47","modified_gmt":"2024-02-11T00:27:47","slug":"how-to-install-a-radiator-in-a-jeep-wrangler-tj-direct-fit","status":"publish","type":"post","link":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/2023\/09\/how-to-install-a-radiator-in-a-jeep-wrangler-tj-direct-fit","title":{"rendered":"How to install a radiator in a Jeep Wrangler TJ. Direct Fit?"},"content":{"rendered":"\n

Radiator Removal and Installation<\/h2>\n\n\n\n
\"\"<\/a><\/figure>\n\n\n\n
    \n
  1. Disconnect negative battery cable at battery.<\/li>\n\n\n\n
  2. Remove the radiator cap.<\/li>\n\n\n\n
  3. Remove the condenser lower seal from the lower core support .<\/li>\n\n\n\n
  4. Drain cooling system drain coolant into a clean container for reuse.<\/li>\n\n\n\n
  5. Remove radiator upper and lower hose clamps Remove radiator hoses.<\/li>\n\n\n\n
  6. Disconnect coolant reserve\/overflow tank hose from radiator.<\/li>\n\n\n\n
  7. 2.4L ONLY – Remove the electric cooling fan.<\/li>\n\n\n\n
  8. 4.0L ONLY – Remove the reservoir tank and power steering reservoir and position out of the way.<\/li>\n\n\n\n
  9. 4.0L ONLY – Remove the four fan shroud mounting bolts . Position the fan shroud back over the fan blades.<\/li>\n\n\n\n
  10. If equipped, disconnect and plug automatic transmission fluid cooler lines.<\/li>\n\n\n\n
  11. Remove six radiator mounting bolts. Position the front axle vent hose to the side.<\/li>\n\n\n\n
  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.<\/li>\n\n\n\n
  13. Lift radiator straight up and out of vehicle taking care not to damage radiator fins.<\/li>\n\n\n\n
  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<\/li>\n<\/ol>\n\n\n\n

    To install:<\/strong><\/em><\/p>\n\n\n\n

    \"\"<\/a><\/figure>\n\n\n\n

    CAUTION<\/strong><\/p>\n\n\n\n

    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.<\/p>\n\n\n\n

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

      <\/p>\n\n\n\n

      COOLANT DRAIN, FLUSH & REFILL<\/h3>\n\n\n\n

      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.<\/p>\n\n\n\n

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

        Radiator Removal and Installation 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… Read More »How to install a radiator in a Jeep Wrangler TJ. Direct Fit?<\/span><\/a><\/p>\n","protected":false},"author":6,"featured_media":80514,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"neve_meta_sidebar":"","neve_meta_container":"","neve_meta_enable_content_width":"","neve_meta_content_width":0,"neve_meta_title_alignment":"","neve_meta_author_avatar":"","neve_post_elements_order":"","neve_meta_disable_header":"","neve_meta_disable_footer":"","neve_meta_disable_title":"","footnotes":""},"categories":[7794,34],"tags":[25992,25991,25993],"class_list":["post-80512","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-auto-repair-articles","category-jeep","tag-jeep-wrangler","tag-radiator-installation","tag-radiator-removal"],"_links":{"self":[{"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/posts\/80512","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/users\/6"}],"replies":[{"embeddable":true,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/comments?post=80512"}],"version-history":[{"count":0,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/posts\/80512\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/media\/80514"}],"wp:attachment":[{"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/media?parent=80512"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/categories?post=80512"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.freeautomechanic.com\/mechanic\/forum\/wp-json\/wp\/v2\/tags?post=80512"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}