Step by Step - H2 Radiator Removal - 2005
I searched the forum for detailed steps on removing an H2 radiator, what I found was that it isn't really that hard. As one member stated, "At the most maybe 2-3 hours without beer. Longer with beer." What I didn't find were the actual steps to remove the darned thing (quite possibly, because it just isn't that difficult). Regardless, I finally found them in an '05 H2 service manual. So, here they are for anybody who needs to remove their radiator and doesn't have a service manual.
1. Drain the cooling system
a) Remove the surge tank fill cap.
b) Raise and support the vehicle.
c) Place a drain pan under the lower radiator hose.
d) Reposition the lower radiator hose clamp.
e) Remove the lower radiator hose from the radiator.
f) Drain the cooling system.
2. Reposition the radiator inlet hose clamp from the radiator.
3. Remove the radiator inlet hose from the radiator.
4. Remove the fan shroud.
a) Loosen the air cleaner outlet duct clamps from the throttle body.
b) Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
c) Remove the air cleaner outlet duct.
d) Remove the radiator inlet hose from the fan shroud retainer.
e) Remove the bolt from the fan shroud.
f) Remove the transmission oil cooler line from the fan shroud retainer.
g) Rotate the slip ring from under the fan shroud.
h) Remove the bolts from the fan shroud.
i) Remove the fan shroud from the vehicle.
5. Reposition the radiator outlet hose clamp from the radiator.
6. Remove the radiator outlet hose from the radiator.
7. Reposition the surge tank inlet hose clamp from the radiator.
8. Remove the surge tank inlet hose from the radiator.
9. Reposition the radiator vent inlet hose clamp from the radiator.
10. Remove the radiator vent inlet hose from the radiator.
11. Remove the engine oil cooler lines from the radiator.
a) Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
b) Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
c) Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed.
d) Discard the retaining rings. Remove the engine oil cooler line from the quick connector fitting at the radiator by pulling straight out from the connectors.
e) Clean all of the components in a suitable solvent, and dry them with compressed air.
f) Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction.
g) Replace parts as necessary.
12. Remove the transmission oil cooler lines from the radiator.
a) Same procedure as for engine oil cooler lines above.
13. Remove the two radiator bolts from the radiator.
a) Located at the top corners of the radiator (engine side of radiator).
14. Lift and remove the radiator from the vehicle
Have fun! And, if your inclined, take a little longer and have a couple of beers along the way like I did!
1. Drain the cooling system
a) Remove the surge tank fill cap.
b) Raise and support the vehicle.
c) Place a drain pan under the lower radiator hose.
d) Reposition the lower radiator hose clamp.
e) Remove the lower radiator hose from the radiator.
f) Drain the cooling system.
2. Reposition the radiator inlet hose clamp from the radiator.
3. Remove the radiator inlet hose from the radiator.
4. Remove the fan shroud.
a) Loosen the air cleaner outlet duct clamps from the throttle body.
b) Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
c) Remove the air cleaner outlet duct.
d) Remove the radiator inlet hose from the fan shroud retainer.
e) Remove the bolt from the fan shroud.
f) Remove the transmission oil cooler line from the fan shroud retainer.
g) Rotate the slip ring from under the fan shroud.
h) Remove the bolts from the fan shroud.
i) Remove the fan shroud from the vehicle.
5. Reposition the radiator outlet hose clamp from the radiator.
6. Remove the radiator outlet hose from the radiator.
7. Reposition the surge tank inlet hose clamp from the radiator.
8. Remove the surge tank inlet hose from the radiator.
9. Reposition the radiator vent inlet hose clamp from the radiator.
10. Remove the radiator vent inlet hose from the radiator.
11. Remove the engine oil cooler lines from the radiator.
a) Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
b) Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
c) Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed.
d) Discard the retaining rings. Remove the engine oil cooler line from the quick connector fitting at the radiator by pulling straight out from the connectors.
e) Clean all of the components in a suitable solvent, and dry them with compressed air.
f) Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction.
g) Replace parts as necessary.
12. Remove the transmission oil cooler lines from the radiator.
a) Same procedure as for engine oil cooler lines above.
13. Remove the two radiator bolts from the radiator.
a) Located at the top corners of the radiator (engine side of radiator).
14. Lift and remove the radiator from the vehicle
Have fun! And, if your inclined, take a little longer and have a couple of beers along the way like I did!
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