RADIATOR
Removal
1. Drain the coolant into clean containers for possible reuse after engine installation. Refer to Section P, Lubrication and Service, for the cooling system capacity.
2. If the radiator is being removed without the complete power module, remove the grille and hood according to the removal instructions in Section B, Structural Components.
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere. An approved recovery/recycle station must be used to remove the refrigerant from the air conditioning system.
3. Refer to Section N4, Heater / Air Conditioner, for the procedures required to properly remove the refrigerant from the air conditioning system. NOTE: The system is charged with HFC-134A refrigerant.
a. Remove the refrigerant hose clamps and receiver/drier (3, Figure 3-1) from the front left side of the radiator shroud. Disconnect the harness from the low pressure switch on the receiver/drier.
b. Remove the clamps and disconnect inlet hose (4, Figure 3-2) and outlet hose (5) at the condenser. Remove mounting hardware (3) and remove condenser (2) from radiator assembly (1).
c. Cap all hoses to prevent contamination. Remove any remaining clamps attaching the hoses and wiring to the radiator shroud. Reposition the hoses and wiring to allow removal of the radiator and shroud assembly.
4. Disconnect the lines at the fuel cooler. Remove all clamps that secure the lines to the radiator.
FIGURE 3-1. RECEIVER/DRIER LOCATION 1. Condenser
2. Accumulator
3. Receiver/Drier
FIGURE 3-2. AIR CONDITIONER CONDENSER 1. Radiator Assembly
2. Condenser
3. Mounting Hardware
4. Inlet Hose 5. Outlet Hose
5. Unclamp and separate all upper hoses between the radiator and the engine.
6. Remove outlet elbows (2, Figure 3-3) and (4) at the bottom tanks. Cap all coolant lines to prevent contamination.
7. Remove and cap the hoses from the radiator top tank and surge tank.
8. Remove the capscrews and lockwashers to free fan guards (1, Figure 3-4) and (2) from radiator shroud (3). The two halves of the fan guard may be disassembled and removed or the complete guard may be moved to the rear to clear the shroud during removal of the radiator.
9. Attach the hoist to the radiator and take up any slack.
NOTE: The radiator and shroud assembly weighs approximately 2600 kg (5730 lbs).
10. Remove upper support rods (2, Figure 3-5) and stabilizer bars (3), if equipped.
11. Remove radiator mounting hardware (4, Figure 3-3) that secures the radiator and to the power module subframe.
12. Loosen the radiator bumpers on both decks. 13. Ensure that all hoses and wiring harnesses
have been removed. Lift the radiator slightly with the hoist and move the radiator forward until it is clear of the engine fan. Move the radiator to a work area for service.
FIGURE 3-3. RADIATOR PIPING, BOTTOM VIEW 1. Drain Cock
2. Outlet Elbow (Front) 3. Radiator Mounting
Hardware
4. Outlet Elbow (Rear) 5. Heat Exchanger 6. Engine Subframe
FIGURE 3-4. FAN GUARDS 1. Fan Guard (LH)
2. Fan Guard (RH)
C03034 7/07 Cooling System C3-5
Installation
1. Attach a hoist to the radiator and lift it into position on the power module subframe. 2. Install radiator mounting hardware (4, Figure 3-
5) at the lower radiator mounting brackets. Do not tighten at this time.
3. Inspect the rubber bushings for upper support rods (2) and replace them if worn or damaged. 4. Install upper support rods (2) and the mounting
hardware at both ends. Do not tighten at this time.
5. Adjust the upper support rods until the radiator is positioned perpendicular to the subframe within ± 3.0 mm (0.12 in.) measured at top of radiator. When the position is established, tighten the upper support rod locknuts and recheck the perpendicularity of the radiator.
6. Tighten radiator mounting hardware (4) at the lower radiator mounting brackets to the standard torque.
7. For added stability, stabilizer bars (3) may be installed. Install the stablizer bars at the radiator brackets and subframe as shown, then tighten the mounting hardware to the standard torque. 8. Install fan guards (1, Figure 3-4) and (2) using
the original mounting hardware.
10. Install the upper hoses between the radiator and the engine. Seat the hoses fully and tighten the clamps securely.
11. Install outlet elbows (2, Figure 3-3) and (4) with new gaskets.
12. Route the lines to the fuel cooler and clamp them in place. Attach the lines to the fuel cooler fittings.
13. Install the air conditioning system components. a. Install condenser (2, Figure 3-2), hoses (4)
and (5), and all clamps.
b. Install receiver/drier (3, Figure 3-1) and clamp the hoses. Attach the harness to the low pressure switch.
c. Clamp all hoses and wiring to the studs using the original clamps. Refer to Section N, Heater / Air Conditioner, for complete instructions on evacuating and recharging the air conditioning system.
14. Install the grille and hood according to the instructions in Section B, Structural Components. Make sure that both radiator bumpers are adjusted and secured.
15. Make sure that all coolant drains are closed, all pipe plugs are installed, and all hoses are connected securely. Service the cooling system with the proper mixture of antifreeze as recommended in Section P, Lubrication and Service. Check for leaks and correct as needed. 16. Start and operate the engine until the cooling system reaches normal operating temperature. Recheck for leaks during engine operation. Turn off the engine and correct any leaks. FIGURE 3-5. RADIATOR MOUNTING
1. Radiator
2. Upper Support Rod 3. Stabilizer Bar
4. Radiator Mounting Hardware
Filling Procedure
The cooling system is pressurized due to thermal expansion of coolant. DO NOT remove the radiator cap while the engine and coolant are hot. Severe burns may result.
1. With engine and coolant at ambient temperature, remove the radiator cap.
Note: If coolant is added using the Wiggins quick fill system, the radiator cap must be removed before adding coolant.
2. Fill the radiator with the proper coolant mixture (as specified by the engine manufacturer) until coolant is visible in the sight gauge.
3. Install the radiator cap.
4. Operate the engine for five minutes, then check the coolant level.
5. If coolant is not visible in the sight gauge, repeat steps 1 through 4 of this procedure. Any excess coolant will be discharged through the vent hose after the engine reaches normal operating temperature.
NOTE: Engine coolant must always be visible in the sight gauge before truck operation.