Radiator Removal and Service

Complete removal and service of the radiator on a 1992 Dodge Viper 8.0L V10, including coolant drain, fan removal, and hose disconnection.

Warnings

Tools required

Parts

• Radiator (if replacing) × 1 — Use OEM specification
• Upper radiator hose (if deteriorated) × 1 — Use OEM specification
• Lower radiator hose (if deteriorated) × 1 — Use OEM specification
• Radiator cap (if replacing) × 1 — Use OEM specification
• Hose clamps (if reusing originals show wear) × 4 — Worm-drive style, appropriate sizing

Fluids

• Ethylene glycol 50/50 coolant — 24 qt

Preparation

1. Park vehicle on level ground and apply parking brake. Place wheel chocks behind rear wheels.
2. Allow engine to cool completely (minimum 2 hours after last operation).
3. Open hood and support with prop rod.
4. Disconnect negative battery cable to prevent accidental fan engagement.
5. Position large drain pan beneath radiator drain petcock location.
6. Remove radiator cap slowly to release any residual pressure.

Procedure

1. 1

   Drain cooling system
   Locate the radiator drain petcock on the driver side lower corner of the radiator. Open the petcock by turning counterclockwise and allow coolant to drain completely into the drain pan. This will take several minutes due to the 24 quart system capacity. Once drained, close the petcock finger-tight only.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove upper radiator hose
   Locate the upper radiator hose connection at the top of the radiator on the passenger side. Using hose clamp pliers, compress and slide the spring clamp back approximately 2 inches from the radiator neck. Twist the hose gently to break the seal, then pull firmly to remove from the radiator. Have a shop towel ready as residual coolant will drain from the hose.
3. 3

   Remove lower radiator hose
   Locate the lower radiator hose connection at the bottom of the radiator on the driver side. Compress and slide the spring clamp back from the radiator neck. Twist and pull the hose to remove. Additional coolant will drain, so ensure the drain pan is positioned appropriately.
4. 4

   Disconnect transmission cooler lines
   The Viper uses a 6-speed manual transmission and does not have transmission cooler lines, so this step can be skipped.
5. 5

   Remove fan shroud assembly
   The electric cooling fan and shroud are mounted to the radiator as a single assembly. Disconnect the electrical connector from the fan motor by pressing the release tab and pulling apart. Remove the 4 fan shroud mounting bolts securing the fan/shroud assembly to the radiator. These bolts are located at each corner of the shroud. Carefully lift the fan and shroud assembly straight up and out of the engine bay as a unit.
   Torque spec

   Fan Shroud Bolts10 Nm (7 lb-ft)
6. 6

   Remove radiator upper mounting brackets
   Locate the two upper radiator mounting brackets, one on each side of the radiator top tank. Each bracket is secured with 2 bolts to the radiator core support. Remove these bolts and set the brackets aside. Note the orientation of any rubber isolators or bushings for reassembly.
7. 7

   Remove radiator from vehicle
   With all hoses, lines, and mounting hardware removed, carefully lift the radiator straight up and out of the engine compartment. The radiator will tilt slightly forward as it clears the lower mounting pins or brackets. Work slowly to avoid damaging the cooling fins on surrounding components. Inspect the lower rubber mounting cushions in the radiator support; replace if cracked or deteriorated.
8. 8

   Inspect and service radiator
   With the radiator removed, inspect for physical damage, fin damage, leaks at tank seams, and debris accumulation. Clean the radiator exterior with low-pressure water and compressed air, working from the engine side outward to push debris through the fins. Check both tanks for cracks or corrosion. If performing pressure testing, use a radiator pressure tester set to the system rating (typically 16 PSI for this application) and submerge in water to check for leaks. If the radiator is being replaced, transfer any sensors or fittings to the new unit.
9. 9

   Install radiator into vehicle
   Carefully lower the radiator into the engine compartment, ensuring it seats properly onto the lower rubber mounting cushions. The radiator should sit level and centered in the core support opening. Align the upper mounting bracket holes with the radiator support.
10. 10

    Install upper mounting brackets
    Position the upper mounting brackets over the radiator and align with the core support mounting holes. Install and hand-tighten the mounting bolts, then torque to specification. Verify the radiator sits securely without excessive movement.
11. 11

    Reinstall fan shroud assembly
    Lower the fan and shroud assembly into position, guiding it down over the radiator and ensuring proper alignment with the mounting holes. Install the 4 fan shroud mounting bolts and torque to specification. Reconnect the electrical connector to the fan motor, ensuring it clicks into place securely.
    Torque spec

    Fan Shroud Bolts10 Nm (7 lb-ft)
12. 12

    Reconnect radiator hoses
    Slide the spring clamps onto the lower and upper radiator hoses approximately 2 inches from the ends. Push the lower radiator hose firmly onto the radiator neck until it seats completely, then slide the clamp into position over the neck. Repeat for the upper radiator hose. Ensure both hoses are fully seated and clamps are positioned correctly to prevent leaks.
13. 13

    Refill cooling system
    Using a funnel, pour fresh 50/50 ethylene glycol coolant into the radiator filler neck until full. The system capacity is 24 quarts. Fill slowly to allow air to escape. Once the radiator is full, install the radiator cap. Start the engine and allow it to warm up to operating temperature with the heater on full hot. Monitor coolant level and add as needed while the system burps air. The level will drop as air pockets evacuate.
14. 14

    Bleed cooling system and check for leaks
    With the engine at operating temperature, check all hose connections, the radiator petcock, and any other disturbed fittings for leaks. The Viper V10 cooling system should self-burp as the thermostat opens, but monitor the radiator level through the cap and add coolant as needed. Allow the engine to run through several heat cycles, then recheck coolant level when cold. Top off as necessary to the full mark on the radiator or overflow tank if equipped.

Reassembly

1. Reconnect the negative battery cable.
2. Verify all hose clamps are properly positioned and tight.
3. Check that the radiator drain petcock is closed and not leaking.
4. Ensure the fan shroud is secure and the fan blade does not contact the shroud at any point.
5. Dispose of old coolant at an appropriate recycling facility.

Verification

• Start the engine and verify the electric cooling fan engages when the engine reaches normal operating temperature.
• Check for coolant leaks at all hose connections, the radiator petcock, and radiator tanks while the system is under pressure.
• Verify coolant level is at the proper full mark when the engine is cold after the first drive cycle.
• Monitor engine temperature gauge during initial test drive to confirm normal operating temperature is maintained.
• Recheck coolant level after 24 hours and top off if necessary, as residual air may continue to evacuate from the system.

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