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Radiator Replacement (8.1L)
Removal Procedure
1. Drain the cooling system. Refer to Draining and Filling Cooling System in the WCC Service Manual.
2. Discharge and recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging in the WCC Service Manual.
3. Remove the air intake duct and the MAF/IAT sensor. Refer to Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Replacement in this supplement.
4. Disconnect the transmission oil cooler lines. Refer to Oil Cooler Line Replacement in this supplement.
5. Disconnect the radiator bypass hose.
6. Disconnect the lower radiator hose.
7. Disconnect the overflow hose from the radiator.
8. Disconnect the transmission control module (TCM) connectors.
9. Disconnect the powertrain control module connectors from the (PCM).
10. Remove the PCM bracket retaining bolts and the bracket with PCM and TCM attached.
11. Remove the upper radiator hose from the radiator and thermostat housing. Refer to Radiator Hose Replacement – Inlet (8.1L) in this supplement.
12. Remove the engine oil fill tube from the oil pipe.
13. Remove the upper fan shroud. Refer to Fan Shroud Replacement – Upper (8.1L) in this supplement.
14. Remove the engine cooling fan from the water pump. Refer to Fan Replacement (8.1L) in this supplement.
15. Remove the lower fan shroud. Refer to Fan Shroud Replacement – Lower (8.1L) in this supplement.
16. Remove the bolt from the engine oil cooler block fitting and separate the fitting. Refer to Engine Oil Cooler Line Replacement (8.1L) in this supplement.
17. Remove the coolant bottle from the bracket.
18. Remove the nuts and bolts from the coolant bottle bracket and engine oil filler tube bracket, and remove the coolant bottle bracket.
19. Remove the screw from the engine oil filler tube bracket and upper radiator frame and remove the filler tube bracket.
20. Remove the radiator filler tube screw.
21. Loosen the clamps and remove the hose and radiator filler tube from the radiator.
22. Remove the auxiliary cooling fans. Refer to Auxiliary Cooling Fan Replacement (8.1L) in this supplement.
23. Remove the dryer filter screws and disconnect the dryer filter from the condenser outlet line. Refer to Receiver Dehydrator Replacement in the WCC Service Manual.
24. Disconnect the refrigerant hose fitting from the A/C condenser inlet. Discard the O-ring seal.
25. Remove the screws and washers from the transmission oil cooler and remove the cooler.
26. Remove the 3 screws and washers from the condenser and engine oil cooler, and from the upper radiator bracket.
27. Remove the condenser and the engine oil cooler.
28. Remove the retainers from the rubber splash shield and the frame.
29. Remove the 3 screws from the outer bracket at the frame.
30. Remove the screws from the outer bracket and inner bracket, and remove the outer bracket.
31. Remove the screws from the inner bracket and upper radiator frame, and remove the inner bracket.
32. Remove the 4 screws from the upper and lower radiator frames.
33. Remove the upper radiator frame from the lower radiator frame.
34. Remove the radiator.
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Full-Timers
in a
2003 Rexhall Aerbus 3550BSL
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