Shown side by side, the new McCulloch Fab radiator is an obvious improvement, but even when compared to a new factory replacement unit the McCulloch unit still offers stouter construction. Also, the new radiator easily accepts all of the factory hoses and connections and offers a direct-fit installation.
In order to complete the installation of the new cooling components on our Cherokee, we sought assistance from Don-A-Vee Chrysler Jeep in Placentia, California. The Don-A-Vee team was well equipped for such an installation and even had the right parts on hand to replace some of the miscellaneous water pipes and hose sections that we'd neglected to order beforehand. Don-A-Vee technician Gary Grinkivich attacked the job with his usual fervor and had it completed in about a day's time. This type of job can be completed at home too, but you will need to make sure you dispose of the old coolant and used components properly.
With parts in place, we noticed an obvious power improvement, chiefly due to the fact that our cooling system was performing as intended. The temp gauge settles in under 180 degrees F during most driving situations, and even fuel economy normalized, putting up numbers much closer to the original advertised fuel-economy figures than the engine had previously offered. Check out the photos and captions for the play-by-play, and take steps to improve your vehicle's cooling system. You'd be a lot cooler if you did.
The factory water pump was then unbolted and pried from the front of the block. Coolant was surprisingly green in respect to the interior of the engine's water cavities. | 
With the thermostat and pump removed, we noticed that the system had not been circulating as intended. Although the pump was still churning fresh coolant through the block, the water cavity in the head was nearly dry and thick with buildup of debris and old coolant. | 
The water pump and thermostat and housing were then installed. The Turbo City thermostat housing is an all-new factory part that is CNC-machined to allow increased coolant flow. Inside the housing, Gary installed a 180 degree F thermostat also from Turbo City. The 180 degree F unit will offer better fuel economy. A 160 degree F thermostat is also offered to create better performance. |
With the fan shroud in place, Gary positioned the new radiator in front of it on the lower radiator mounts. | 
The upper radiator hose was then attached to the radiator using a new hose clamp. | 
The upper radiator mounts were bolted in place at the top of the radiator. Also note the integrated trans-cooler mounts on either side of the radiator. |
The remaining radiator connections were then completed. We sourced a second steel pipe from Don-A-Vee parts to replace the rusted stock part. | 
The old serpentine belt was worn and cracked - a condition that could lead to failure if not replaced. | 
Gary routed the new Goodyear Gatorback Poly-V serpentine belt following the factory routing. |
The remaining thermostat-housing lines were connected, and the temperature sensor was plugged in. | 
With the cooling parts in place, Gary added a mix of coolant and water to the new McCulloch radiator. After running the engine at idle and at 2,000 rpm for about 10 minutes, we continued to add water until the cooling system was filled. Once the radiator was topped off, we test-drove the vehicle for about 5 miles to make sure we didn't have any leaks. | 
Don-A-Vee Chrysler Jeep knows more about Jeeps than just basic service. The crew maintains and races the #1774 JeepSpeed Challenge Cherokee XJ. |