How do you replace Jeep Wrangler radiator?

Answer 1

Replacing A Jeep Wrangler Radiator.IMPORTANT: Ensure the engine temprature is cool before begining. This write-up is modeled after a 2002 TJ. If you have an auto transmission and you're installing a new radiator, ensure your replacement radiator has two nipples on the bottom for cooler lines.

1) Remove radiator cap to enable the coolant to drain better.

2) Locate the drain plug, normally located on the bottom of the radiator. Allow the coolant to drain into a bucket to be disposed of responsibly.

***Don' forget to also drain the coolant form the reservoir by simply removing the overflow hose. Depending on what year Wrangler you own will dictate how the reservoir is removed. YJ's are mounted with screws on the driver side engine compartment. TJ's are removed by pulling on the container in an upward direction, separating it from the fan shroud.

3) Remove the upper radiator hose by removing two hose clamps. This hose is about 2" in diameter, located on the passenger side, opposite of the radiator cap. Depending on what kind of clamps you have, you will either have to use a pair Channel Lock pliers or a screwdriver to remove.

***Check for serviceability of the hose. Replace if nesessary. Look for soft spots, hard spots, cracks or small rips/tears. Hose is cheap, replacing an engine head gasket ,warped head, or cracked engine block isn't.

4) Remove lower radiator hose in the same mannor as the upper. This hose looks the same as the upper but is located on the radiator's driver side bottom. It attaches to the water pump inlet. Inspect this hose using the same criteria as the upper hose and replace if necessary.

NOTE: If you have an automatic transmission, you will have two additional hoses about 5/8" in diameter located on the bottom of the radiator. You must remove the two hoses from the radiator. There WILL be Transmission Fluid coming from the hoses so ensure you have a recepticle or rags to catch whatever spills out. Cap off the ends of the hoses with a plug or put two bolts about 5/16" in the ends.

5) Remove the 3 bolts from each side of the plastic fan shroud, holding it to the radiator. Move the fan shroud towards the engine, allowing to rest on the fan blades.

6) Remove 3 more bolts on each side of the radiator, holding it to the Jeep's front grill. Remove the top bolt of each side first but reinsert them about 3 turns each so you can easliy remove them by hand later.

7) After removing the middle and bottom bolts from each side, remove each of the top bolts you reinserted, being careful not to let the radiator fall down. It helps to have another person assist with this step.

*** If you have an automatic transmission, remember there will still be oil in the bottom of the radiator, So as you remove it, watch where & how you put it down.

8) To install the new/replacement radiator, simply reverse the steps above. DON'T FORGET THE TRANSMISSION LINES.

NOTES:

*When installing the hoses, ensure they are fully seated against the radiator, water pump, & thermostat housing.

*If you have hose clamps that are a worm drive and require a screwdriver, make sure not to overtighten. Tighten only until you see the clamp makes a slight impression in the hose. Over-tightening will cut into your new hoses.

*It's always best to use a new radiator cap. It will ensure the cooling system is not overpressurized and blow a hose or your radiator.

*When filling the radiator, use de-mineralized or purified water. It will keep deposits from clogging the inside of the radiator over time.

ANSWER

Draining the Cooling System

• Locate the petcock valve on the lower right corner of the radiator and place a waste oil collection pan underneath it.

• Open the petcock valve by turning it counterclockwise, using needle nose pliers.

• Wait until all the coolant has drained out then close the petcock valve by turning it clockwise.

• Removing the Radiator

• Loosen the hose clamp that connects the upper radiator hose to the radiator using a Phillips head screwdriver. Then pull the upper radiator hose off the radiator.

• Loosen the hose clamp that connects the lower radiator hose to the radiator using a Phillips head screwdriver. Then pull the hose off the radiator.

• Unscrew the transmission cooler lines from the radiator (automatic transmission only) using a wrench.

• Unscrew the bolts that secure the radiator to the core support, using a socket.

• Lift the radiator straight up to remove it from the vehicle.

• Installing the Radiator

• Lower the radiator into position behind the core support. Be careful: the cooling fins are thin and can be easily damaged.

• Screw the bolts that secure the radiator into the core support. Tighten with a socket.

• Thread the transmission cooler line fittings into the radiator. Tighten with a wrench.

• Slide the lower radiator hose onto the fitting on the bottom of the radiator. Slide the hose clamp over the fitting and tighten with a Phillips head screwdriver.

• Slide the upper radiator hose onto the fitting on the top of the radiator. Slide the hose clamp over the fitting and tighten with a Phillips head screwdriver.

• Fill the engine with a 50/50 mix of antifreeze and water.

• Run the engine and visually inspect for leaks.