How to Put a Radiator in a 2002 Jeep Grand Cherokee

The 2002 Jeep Grand Cherokee was equipped with a 4.0-liter in-line six-cylinder engine in the base model. The other engines that were available with the 2002 Grand Cherokee included a 4.7-liter V-8 and a 4.7-liter high-output V-8. The cooling temperature on the 2002 Grand Cherokee is maintained by both the radiator and the water pump. The radiator on the 2002 Grand Cherokee can crack in certain places, requiring replacement.

Instructions

Raise the hood on the Grand Cherokee. Remove the negative battery cable from the battery with a ratchet and socket. Tuck the battery cable to the side of the battery so there is no opportunity for it to make contact with the battery post during this project.

Raise the front of the Grand Cherokee with a jack. Place jack stands beneath the front sub-frame rails on both sides of the engine, or beneath the front axle housing if you have a four-wheel-drive model. Remove the radiator pressure cap from the top of the radiator. Lie beneath the front of the Jeep and slide yourself in position to access the lower radiator petcock. Slide a drain pan beneath the petcock with the majority of the pan behind the radiator. Open the petcock, with pliers if needed, and allow the radiator to drain into the pan.

Close the petcock after approximately five to seven minutes, or until the radiator has only a very thin drain line or drip. Move the drain pan beneath the lower radiator hose and pull the hose clamp off the radiator with pliers. Pull the lower radiator hose off the radiator and allow the engine to drain into the pan for about five minutes. Leave the hose draining into the pan for the duration of the project.

Raise the Jeep off the jack stands, then remove the stands from beneath the Jeep. Lower the Jeep to the ground slowly. Slide the upper hose clamp off the radiator and about 6 inches rearward with pliers. Install radiator locking pliers or flat-nosed vice grips onto the upper radiator hose to pinch the hose shut completely. Pull the upper radiator hose off the radiator.

Remove the radiator cooling fan electronic connector by hand. Remove the power steering fluid reservoir from the top fop of the radiator shroud with a ratchet and socket. Set the reservoir to the side of the shroud. Remove the radiator reservoir hose from the filler neck by hand.

Remove the radiator fan shroud mounting nuts from the radiator core support with a ratchet and socket. Pull the fan shroud and electric fan assembly straight upward and out of the engine compartment. Set the fan assembly outside your work area.

Remove the automatic transmission lines, if equipped, from the old radiator using a quick-disconnect tool 6935 or equivalent. Push the quick-disconnect tool onto the transmission fitting, then pull the fitting off the radiator. Repeat this for the second transmission fitting. Remove the mounting bolts from the upper radiator core support with a ratchet and socket, then remove the radiator core support. Set the core support outside your work area.

Detach the radiator from the radiator-to-air conditioning condenser assembly brackets, if the Jeep is equipped with air conditioning. Remove the bolts attaching the radiator to the brackets.

Pull the radiator straight upward and out of the engine compartment. Set the radiator with the hose openings upward, so that it does not spill or leak antifreeze on the ground. Set the new radiator on a large piece of cardboard, or in the box it came packaged in, directly next to the old one. Transfer the transmission fittings from the old radiator to the new, unless the new radiator came with new fittings. Tighten the fittings snugly with a ratchet and deep-well socket. Use the transmission hole caps on the new radiator to plug the transmission line holes on the old radiator.

Turn the radiator filler neck on the old radiator counterclockwise, using large pliers if needed. Do not squeeze the plastic neck hard or you will break it. Install the filler neck onto the new radiator and tighten it snug, using pliers if needed. Install the new radiator straight downward into the two bottom mounting holes on the front frame.

Install the automatic transmission lines, if equipped, onto the new radiator using the quick-disconnect tool to assist you. Push the quick-connect tool over the fitting on the line, then install the line. Push the line onto the radiator with one hand, and remove the quick-connect tool with your free hand. Repeat this step to attach the second transmission line onto the radiator fitting.

Install the radiator-to-air conditioning condenser bracket bolts and tighten them snugly with a ratchet and socket. Install the upper radiator core support and tighten the bolts to 86 inch-pounds with a torque wrench and socket. Connect the upper radiator hose, then remove the clamp from the hose that you have, pinching it shut. Slide the radiator hose clamp over the hose where it joins to the radiator using pliers.

Install the electronic cooling fan and shroud onto the new radiator. Tighten the shroud bolts to 31 inch-pounds. Connect the cooling fan electrical connector by hand. Install the power steering reservoir onto the new radiator fan shroud, and tighten the mounting bolts snugly. Install the radiator coolant reservoir hose to the filler neck on the new radiator.

Raise the front of the Jeep with the jack and place the jack stands beneath the Jeep again. Lower the Jeep onto the stands. Lie beneath the Jeep and slide yourself into position to access the lower radiator hose. Push the hose onto the new radiator, then slide the hose clamp with pliers forward to where the hose joins to the radiator.

Raise the Jeep off the stands, then remove the stands from beneath the Jeep. Lower the Jeep to the ground slowly. Add engine coolant to the Jeep until the radiator is completely filled. Install the negative battery cable onto the battery, and tighten it snugly with a ratchet and socket.

Start the Jeep engine with the radiator cap off. Check your radiator and transmission fittings immediately and shut the engine off if any are leaking. Adjust the leaky fitting, then restart the engine. Allow the engine to run for approximately 15 minutes. Turn the heater control switches to full fan speed, defrost position and full heat.

Check the transmission fluid level while the engine is idling. Determine the fluid level on the dipstick, according to the temperature of the engine: If the engine is only moderately warm, the fluid should be between the "Cold" and "Hot" markings. Add transmission fluid, with a transmission fluid funnel if needed, in small amounts until the transmission is full again.

Monitor the filler hole on the radiator as air bubbles escape from the cooling system. Add coolant to continually refill the radiator, until all of the air pockets are removed. Squeeze the upper radiator hose with your hand gently to help push any residual air pockets out of the upper hose. Install the radiator pressure cap and tighten it when you are done bleeding the air out of the radiator.

Spray the rear side of the cooling fan shroud and new radiator with a water hose. Remove the Jeep from your work area. Spray any spilled coolant puddles with water, until the coolant is heavily diluted and is not showing up green in your driveway.

Pour the coolant from your drain pan into the empty coolant bottle you filled the engine with. Turn the old radiator over the drain pan, so the lower hose fitting is aimed into the pan. Tip the radiator to drain all the remaining fluid from the radiator into the drain pan. Empty the remaining contents of the pan into the coolant bottle.

Take the coolant bottle and the old radiator to your local auto repair facility; they should take the radiator and coolant at no charge to you, and they are properly trained at the disposal of these items.