Champion Radiator Aluminum 3 core swap

WARNING,, THIS RADIATOR FAILED 30,000 MILES LATER

So I finally found some time to do this swap today.
This is how it went and what needs to be done with a 3.4, 5 speed tacoma 1997.

The 3.4, 5 speed has a radiator core that is 20.75” tall.
The Champion 3 core radiator for this swap is a little shorter in height at 18.90”.
These measurements are the core height that does not include the tanks FYI.

The swap is straight forward as in any radiator replacement.

The Champion radiator is (2.5”) almost 3” thick and makes the stock core .75 thick radiator look pretty silly when it’s side by side.

The 3 row Champion Radiator is huge compared to the junky plastic tank stock radiator single core.

1) The two hiccups you will have is the stock lower radiator hose will not fit.
2) The fan shroud will need to be cut where the lower radiator hose connects and the radiator peacock sticks out.
3) The Champion Radiator cap is junk that comes with the radiator, ( they tend to leak and don’t seal well to the radiator) so spend 12.00
and get a good quality replacement cap.

Otherwise it’s all plug and play.

The lower radiator hose you will need is a gates part number 22120.
Make sure when you install the hose that the bend in the hose is twisted away from the shroud to give you extra clearance.
This hose you will need to cut about 1.5” or so on either end.
You will have to make a few cuts to get it correct for the final fit.

The shroud I put over the new radiator and took a marker and marked the areas to cut out.

Got my grinder and razor out and away I went.

Make sure you give extra room for both the cuts for the new hose and peacock.

The lower hose was a pain for me, so maybe connect the lower hose after you bolt the radiator it while you have extra room before the shroud is attached.
The new gates hose will be very tight on both ends, make sure you wet down
the hose for it to slide on easier.
The OEM compression clamps will fit but you will have to fight to get them on.
Or get a set of screw on adjustable clamps.

I put in a new thermostat while I was there.

REMEMBER THE THERMOSTAT JIGGLE VALVE IS POSITIONED AT 6 OCLOCK,

NOT 12 OCLOCK

So now I’m ready for some hot summer days.


If you have a v6 automatic the bottom of the shroud will have to be cut differently
as it is 2” taller.

Radiator is 203.00 free shipping on ebay

If you do this mod for the v6, the 3.4, 5speed shroud will
fit the best with cut outs for petcock, trans lines (if you have an auto) and lower hose.

The 3.4 auto shroud is 2” tall then the 3.4, 5 speed shroud.

The 4 banger shroud will NOT work with the v6 motor as it’s centered differently.

I’m thinking this radiator will work with both the 4 banger motors and the original shroud without any mods

Fill antifreeze from the top radiator hose on the engine side by bending the hose up at a 45 degress first to make sure there is antifreeze on the block side as the stat is closed and will not fill up the block side fully and remember to open the
heater valve and burb the system as the heater hose valve is higher than the radiator cap.

Also use some silicone spray to help slid on the ends of the lower radiator hose
as its 1/8” smaller than the ends it goes on

IM ADDED THIS INFO FROM A YEAR LATER, 35,000 ADDED, AS MY RADIATOR IS LEAKING

SOME OF THESE RADIATORS ARE HAVING LEAKING ISSUES INCLUDING MINE.
IT MIGHT BE A QUALITY CONTROL ISSUE, OR A MOUNTING ISSUE.

SO BE WARNED

The Champion has NO rubber bushings designed into its radiator for flex.

So I’m thinking if you put a rubber bushing in between the radiator and the front cowling, radiator support it might be the trick and there would be some play or flex available.
You will have to drill out the radiator nut hole so the bushing tail section can
fit in the radiator support and has some wiggle room.


The bushings are made by Hillman at Lowe’s



Checkout the photos.

 

Sic install and write up!

 

Just ordered one, now to get a new thermostat.

 

Saving this in my bookmarks for when it's time for a new radiator. Thanks! Love the look of that aluminum tank!

 

Oh yea, I think I ended up added an additional half gallon of antifreeze for the larger radiator
FYI, get an extra gallon for this swap.

 

If my rad wasn't only a year old I'd order one. Looks like it is the right size for my existing shroud too.

 

John, that's some radiator!

 

Great writeup and pics!

 

Awesome, thanks for the write up. I have mine still in the box. I need to get this done. I want to order the HPS silicone hoses in black but they are always sold out.

 

Thanks for write up with clear pictures of were to trim the shroud.

Do you think the fan could be removed with the radiator installed? Looks a little tight and maybe the fan won't clear the studs?

 

When installing this radiator you do NOT have to remove the fan or the fan hub.

If you want to remove the fan hub or the fan clutch the fan shroud will have to be removed but I do not believe you will have to remove the radiator

 

I thinking about maintenance items like timing belts and water pumps were the fan comes off. Would the radiator need to be removed?

 

I don’t believe so, it’s not that tight.

When installing this radiator you do not have to remove the fan or the fan hub.

If you want to remove the fan hub or the fan clutch the fan shroud will have to be removed but I do not believe you will have to remove the radiator for these items to be replaced.

 

You can see with the shroud removed there is plenty of room still for those maintenance issues

 

That looks awesome. What are you seeing improvements in from the swap?

 

Yes, inquiring minds want to know. I assume you have a scan gauge to monitor the temperature with that supercharger in your truck. Before, and after temps?

 

So I’ve put on a few hundred miles only, but the temp is now from 188-190 and has not gone above that but once 191 when pushing the supercharger very hard.
Before my temps would run up to 200 when pushing the supercharger hard. Now pushing the supercharger hard hit 191 once, so it’s all good news. The average temp now is at 188 degrees.
The death to these 3.4 motors is heat because of the aluminum heads and can cause a gasket getting blown.
Too much heat=blown heat gasket

This is just plain good insurance and with less temps.
Yes I have a scan guage II

 

Did a close inspection today, everything looks perfect, but did see a little antifreeze leaking from the petcock, The petcock is made of metal with a brass fitting compared to the stock plastic petcock.
So I did need to tighten up the threaded metal part that has silicone tape a bit tighter to stop the leak.
So make sure this part is tight before the install.

 

My temp at its highest fluctuates. It use to be 203, now it reads 212-214. I’ve got to bang this out while I have the time...

 

Wow that is a decent improvement in cooling performance! We have very hot summers here (regularly 110-115 ambient) and the truck doesn't seem to mind the heat but I'm not sure what temps I'm getting in my engine. Still might have to consider this upgrade for the next time the plastic tank cracks.