CSF Radiator Install

CSF Radiator Install
December 2005

The following images document the removal of the factory radiator and the installation of a CSF Radiator on a 2000 Jeep Wrangler TJ Automatic 6-Cylinder.


Factory radiators are prone to leaking.  The crimped metal that holds the very top of the radiator to the radiator body works loose over time, causing a small leak of anti-freeze.  We used to tighten the crimps with a punch and hammer to slow the leak.  One cold morning the top cracked and we were forced to use Permatex Epoxy (life saver) on the crimp area to stop a bad leak.  We purchased a new radiator that did not have a crimp design, the CSF Radiator, and here's the install process.

The first part of removing the stock radiator was to remove the overflow reservoir.  We removed the reservoir hose from the radiator by pulling on it.  Then, we removed the reservoir itself by pressing the button highlighted in the below image and pulling up on the reservoir.  This removed it from the fan shroud.

We then removed the silver colored radiator cap.  After which, we drained the anti-freeze from the radiator by turning the valve at the bottom of the radiator.  If we had no valve, we would have drained the fluid when we detached the hoses in subsequent steps.

After we gave the intake hose a few squeezes to flush any residual fluid out, we removed the hose by loosening the hose crimps and wiggling it free.

Image of the hose removed.

We located the output hose at the bottom of the radiator and disconnected it.  This hose contains fluid, so we had a bucket ready.  It was not necessary to remove the hose completely, we just disconnected it from the radiator.

We were working on a Jeep with an automatic transmission, so we needed to disconnect the two hoses that transfer automatic transmission fluid (ATF) to cool the transmission. A bucket was needed here to catch the fluid.  Once disconnected, we propped the hoses upward to keep in any additional ATF from spilling and being wasted.

Image showing the disconnected hoses.

Using an 11mm socket, we removed the 2 drivers side screws holding the fan shroud to the radiator.

Using an 11mm socket, we removed the 2 passenger side screws holding the fan shroud to the radiator.

After all 4 screws were removed, the fan shroud can be pulled away from the radiator.  We left it propped on the fan.

There are 6 bolts holding the stock radiator to the Jeep body.  The three on the drivers side are located in the picture below and required a 10mm socket to remove.

Also using a 10mm socket, we removed the 3 passenger side bolts.

 With the bolts removed, we lifted the stock radiator out of the Jeep.  The fan shroud stayed propped on the fan, out of the way.

Image of the removed radiator.  A thin radiator remains, for the air conditioning.  Note the stock radiator in the distance.

The fins on radiators are extremely fragile, so we took extreme care not to brush them against any surface as we slowly lowered the new radiator into the Jeep.  Removal of the fan and fan shroud was not needed.

We then installed the 6 bolts to hold the radiator in place.

We then installed the 4 bolts to hold the fan shroud to the new radiator.

Image of the new radiator and old fan shroud bolted in place.

We re-attached all three bottom hoses.

Image of the hoses re-attached.

We then connected the top hose.

Bottom hoses re-attached.

We used a hose clamp on the bottom hoses instead of the stock clamps to get a tighter seal.  The stock hoses were a little dry rotted.  We eventually replaced the hoses.

We installed the reservoir and reservoir hose.  We used a hose clamp on the reservoir hose.  We filled the reservoir with anti-freeze to the fill line.

We added anti-freeze directly to the radiator via the top cap, which we also installed.  Note the hose clamp on the reservoir hose to get a good seal.

We then added ATF to the transmission to compensate for lost ATF from the old radiator.

We ran the vehicle, checked for leaks, and applied fluid to get us to the proper levels.