Cooling System: Service and Repair

Cooling Module
Removal
All Vehicles
1. Remove the air cleaner. For additional information, refer to Powertrain Management.





2. Remove the air cleaner intake pipe.





3. CAUTION: Make sure that the air conditioning condenser is not damaged when installing the retaining straps.

NOTE: To allow the cooling module to be partially lowered and supported when the radiator support beam is removed, suitable retaining straps must be installed to the air conditioning condenser.

Loosely attach suitable retaining straps to the air conditioning condenser.
4. Drain the cooling system. For additional information, refer to Scooting System Draining, Filling and Bleeding.





5. Detach the lower coolant hose from the radiator and position to one side.





6. Reposition the coolant hose from the engine oil cooler to the thermostat housing and secure it to the front cross member using a suitable retaining strap.
7. Lower the vehicle.





8. Detach the radiator vent hose from the radiator.





9. Detach the upper coolant hose from the radiator.





10. Disconnect the cooling fan motor control module electrical connectors.
11. Raise the vehicle.





12. Remove the air splitter grille.





13. Remove the front towing eye trims.

Vehicles With Automatic Transmission





14. Detach the power assisted steering oil cooler inlet and return pipes.
- Left-hand side shown, right-hand side similar.
- Allow the power assisted steering fluid to drain into a suitable container.
- Seal the oil cooler inlet and return pipes and the oil cooler using suitable plugs.

Vehicles With Manual Transmission





15. Detach the power assisted steering oil cooler inlet pipe.
- Allow the power assisted steering fluid to drain into a suitable container.
- Seal the oil cooler inlet pipe and the oil cooler using suitable plugs.

All Vehicles





16. Remove the radiator support beam.





17. CAUTION: Apply suitable tape to the right hand side lower section of the front bumper to prevent damage to the paintwork from the air conditioning pipe when the cooling module is lowered. Failure to follow this procedure may cause damage to the vehicle.

Remove the right-hand side air conditioning condenser retaining bolt from the radiator.





18. Lower the cooling module and the air conditioning condenser to a position where the air conditioning pipe is forward of the front bumper.





19. Remove the left-hand side air conditioning condenser retaining bolt from the radiator.

Vehicles With Automatic Transmission





20. NOTE: The power assisted steering oil cooler remains captive to the automatic transmission oil cooler.

Detach the automatic transmission oil cooler from the radiator.
- Left-hand side shown, right-hand side similar.





21. CAUTION: Do not allow the power assisted steering oil cooler and automatic transmission oil cooler to hang on the automatic transmission oil cooler pipes. Failure to follow this instruction may cause damage to the vehicle.

Position the power assisted steering oil cooler and the automatic transmission oil cooler to one side and secure with suitable retaining straps.

All vehicles





22. Detach the cooling module from the air conditioning condenser.
- Left-hand side shown, right-hand side similar.





23. CAUTION: Make sure that the radiator and the air conditioning condenser are not damaged during the removal of the cooling module.

Remove the cooling module.

Installation
All vehicles





1. CAUTION: Make sure that the radiator and the air conditioning condenser are not damaged during the installation of the cooling module.

Install the cooling module.





2. Attach the cooling module to the air conditioning condenser.
- Left-hand side shown, right-hand side similar.

Vehicles With Automatic Transmission





3. Install the automatic transmission oil cooler to the radiator.
- Left-hand side shown, right-hand side similar.

All Vehicles





4. Install the left-hand side air conditioning condenser retaining bolt.
- Tighten to 7 Nm.





5. Install the right-hand side air conditioning condenser retaining bolt.
- Tighten to 7 Nm.
6. Lower the vehicle.





7. CAUTION: Do not over tighten the retaining straps. Failure to follow this instruction may cause damage to the vehicle.

NOTE: To allow installation of the radiator support beam, install retaining straps to the radiator to hold the cooling module in position.

Install suitable retaining straps to the radiator. Align the cooling module to the upper isolator mounting points.
- Carefully tension the retaining straps to hold the cooling module in position.
8. Raise the vehicle.





9. Install the radiator support beam.
- Tighten to 25 Nm.

Vehicles With Automatic Transmission





10. Connect the power assisted steering oil cooler inlet and return pipes.
- Left-hand side shown, right-hand side similar.

Vehicles With Manual Transmission





11. Connect the power assisted steering oil cooler inlet pipe.

All Vehicles





12. Connect the lower coolant hose to the radiator.





13. Remove the retaining strap from the engine oil cooler coolant hose.
14. Install the undertray.





15. Install the front towing eye trims.





16. Install the air splitter grille.
- Remove the protective tape from the front bumper.
17. Lower the vehicle.





18. Remove the retaining straps from the air conditioning condenser and radiator.





19. Connect the cooling fan motor module electrical connectors.





20. Connect the upper coolant hose to the radiator.





21. Connect the radiator vent hose to the radiator.





22. Install the air cleaner intake pipe.
23. Install the air cleaner. For additional information, refer to Powertrain Management.
24. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding.
25. Check and adjust the power assisted steering fluid level. For additional information, refer to Steering and Suspension.