Radiator: Service and Repair

Removal
1. Disconnect negative battery cable from battery.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

2. Drain cooling system.
3. Remove the front engine compartment supports and upper radiator crossmember.
4. Remove hose clamps and hoses from the radiator.
5. Disconnect fan module wire connector.

Fan Module Lower Attachment Points:

6. Remove fan module fasteners and clips. Lift fan module upward to release from lower attachment points and remove fan module.

CAUTION: Avoid bending the condenser inlet tube. Care should be taken not to damage radiator or condenser cooling fins or water tubes during removal and installation.

Radiator To Air Conditioning Condenser Mounting:

7. Remove the air conditioning condenser mounting screws.
8. Radiator can now be lifted from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes.

Installation
1. Install radiator into engine compartment making sure the lower mounting post are engaged into the lower mounting isolators.
2. Attach air conditioning condenser to radiator. Tighten mounting screws to 5 Nm (45 inch lbs.).
3. Install fan module to radiator. Attach retaining clips and tighten fasteners to 5 Nm (45 inch lbs.).
4. Connect fan module electrical connector.
5. Install radiator hoses and clamps.
6. Install upper radiator crossmember and engine compartment supports.
7. Connect negative battery cable.
8. Fill cooling system with coolant.
9. Operate engine until it reaches normal operating temperature. Check cooling system for correct level.