This is the first step to the process of replacing the radiator. This is a picture of my Jeep before the project began.

Step 1:

Dis-connect the negative cable from the battery.

Step 2:

Start by turning the petcock on the radiator counter-clockwise, which allows the radiator to drain The petcock is on the left side of the radator. (I took a picture of the new radiator to show where it is).

Step 2.5:

This is a picture of the anti-freeze draining out. Be sure that you properly dispose of the anti-freeze. (Don't just dump it in the ground. There are other ways to dispose of it, just ask your local auto parts store).

Step 3:

Take out the screws for the grill. This will aid you in pulling out the old radiator and putting the new one in. However, the grill is connected to the front bumper and will not completely come off (unless you remove the whole front bumper (which I did not do)).

Step 4:

Remove the upper and lower radiator hoses. This is a picture of the upper hose only. The lower radiator hose is located on the right side of the Jeep at the lower part of the engine. You can remove the constant-tension clamps by using a pliers (I replaced the constant-tension clamps by a set of clamps that are tightened down using a flat-head screwdriver, which are much more reliable). The transmission oil cooler lines also need to be removed (remove the rubber hoses from the metal lines that are attached to the radiator. The metal lines do not need to be removed from the radiator itself until the radiator is removed).

Step 5:

Remove the main raidiator screws (which are pictured) and the A/C condensor screws (not pictured, but just in front of the main screws).

Step 6:

The A/C condensor screws, as well as the main radiator screws can be unscrewed by sticking the socket through the grill.(They are both 10mm sockets). After the radiator screws and hoses are removed, the radiator can be yanked out of the Jeep. It does take some muscle to get it out, but it will come out with the electric fan attached or without it attached. (I did remove the fan before I pulled out the radiator, but I installed the new one with the fan attached).

Step 7:

Remove the screws to the front brace. There are 4 - 10mm screws as well as 4 - 5/32" Allen screws (These are actually Torx screws, but the 5/32" allen wrench fits them). Removing the front brace will allow the radiator mounts to clear the brace while the radiator is being removed. Be careful not to break the tabs off that help to hold the grill on (I broke these tabs off by accident, but it does not seem to affect the way that the grill is held on). The radiator and fan assembly can now be completely removed.

Step 8:

Re-attach the electric fan assembly to the new radiator and install it into the Jeep. Also, attach the old metal transmission oil lines to the radiator BEFORE the fan assembly is attached (Put teflon tape onto the threads on the radiator so that it does not leak). DO NOT FORGET the transmission oil lines. I forgot to attach the upper line, and it was a pain to attach them after the radiator was installed. (Attach the transmission lines, and then attach the electric fan assembly).

Step 9:

This is a picture of the new radiator installed in the Jeep. Now, screw in the 2 - 10mm screws, which mount the radiator to the frame and the other 2 - 10mm screws which attach the A/C condenser to the radiator. You can then put the 4 - 10mm screws and 4 - 5/32 allen screws back into the front brace.

Step 10:

After the radiator is mounted, attach the NEW hoses and tighten down the NEW clamps. (Do yourself a favor and get rid of the constant-tension clamps and get a set that you tighten with a screwdriver). Attach the transmission oil lines and the lower radiator hose to the radiator and tighten it down with a NEW clamp.

Step 11:

The project is completed. Be sure that all the hoses are tight and that you dispose of the anti-freeze properly. You can now fill up the cooling system with a 50/50 mix of anti-freeze/water. My Jeep took almost 6 liters of 50/50 mix total . Fill up the radiator through the radiator itself (It took about 4-5 liters. Attach the battery and start the engine. After driving it, it took another 1-2 liters in the reservoir).