Usage:
769C ( 01X1-3144)
Reference: Service Manual, Parts Book, Maintenance Guide
Introduction
Installation of a folded core radiator will improve servicability and improve resistance to plugging from trash.
Parts are now available from the Parts Department for installation of a folded core radiator.
Necessary Parts
Assembly Procedure
1. Drain the coolant from the radiator and remove the radiator. See the Service Manual for the correct procedure.
2. Put 2W2007 Tank Assembly (1) in position on blocks as shown. Remove plugs (2), and clean the surface of all foreign material.
3. Using liquid soap as a lubricant, install eight 8N5130 Seals (3) and seven 8N7139 Seals (4) in the bottom tank in the sequence shown.
4. Install 2W2015 Channel (5) [R.H.] and 2W2014 Channel (6) [L.H.] on the bottom tank with 0S1588 Bolts and 5P1075 Washers. NOTE: Do not tighten four bolts (7) at this time.
5. Install 4W6902 Plate Assembly (8) [stiffener] with four 0S1594 Bolts and 5P1075 Washers. Do not tighten the bolts at this time.
6. Using liquid soap, coat the top of the seal, and install fifteen 2W5542 Core Assemblies (9). NOTE: Make sure each core assembly is seated correctly in the seal.
9. Install 2W2019 Straps (13) and 2W1993 Plate (14) with four 0T0573 Bolts and 5P1075 Washers [each side].
10. Install 2W2020 Bracket Assembly (15) with 0S1594 Bolts and 5P1075 Washers [each side]. Do not tighten the bolts at this time.
11. Using liquid soap, install a seal on top of each core assembly. Coat the top of the seal, and install radiator top tank (16) with 2W2003 Strap (17).
12. Install eight 0S1590 Bolts (18) with 5P1075 Washer. Install nine 0S1594 Bolts (19) with a 5P1075 Washer.
14. Install a 1S0286 Stud in the radiator top tank at location (B). Tighten the stud to a torque of 54 ± 7 N·m (40 ± 5 lb ft).
15. Remove cover and valve assembly (21) from the former top tank. Install the cover and valve assembly on the new top tank with two 5S4629 Gaskets. Tighten all bolts at this time.
Installation Procedure
1. Most of the original radiator parts can be used to install the folded core radiator assembly in the truck.
2. The following steps give only the procedure for installing the new or additional parts.
5. Install former shield assemblies (4) with 9K8115 Bars (5), former bolts and washers.
7. Install existing elbow (7) with a new 4N1419 Gasket, hose and clamps.
8. Install existing tube assemblies (8) with new 4N1418 Gaskets.
9. Install 4W3654 Tube Assemblies (9) with new hoses and clamps.
10. Install all former clips and plastic ties as necessary. Check to make sure all former electrical wires and lines have been connected.
11. Install all parts that were removed earlier (see the Service Manual).
12. Fill the cooling system with coolant (See the Maintenance Guide).
13. Start the engine and check for leaks.