Procedures

RADIATOR

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.

NOTE: Capture all residual fluid spillage and store in suitably marked containers. Inspect condition of all clamps and hoses, replace as necessary.

1. Drain coolant from radiator only.
2. Remove headlamps.
3. Remove front cross member together with front grille.
4. Remove front bumper.
5. Remove bolts holding air charge hose to sheet metal and inter-cooler.





6. Detach air intake pipe at the body (Fig. 9).
7. Detach both coolant hoses at the coolant reservoir (Fig. 9).
8. Unplug wiring connector at coolant level sensor (Fig. 9).
9. Detach coolant hose at bottom right of radiator (Fig. 9).
10. Detach transmission cooler lines at radiator (Fig. 9).
11. Remove the radiator trim from the left and right (Fig. 9).
12. Remove radiator fan.
13. Remove bolts securing inter-cooler to radiator.
14. Remove screws and upper radiator trim from radiator.
15. Move condenser/inter-cooler/power steering cooler assembly forward.
16. Lift the radiator assembly up and out of the rubber grommets (Fig. 9).





17. Take off charge air cooler together with cooling loop of the steering at the radiator (Fig. 10).
18. Remove bottom radiator trim (Fig. 10).
19. Detach coolant hose at radiator.
20. Detach coolant pipe together with coolant hose at the fan shroud.
21. Remove radiator fan shroud (Fig. 10).

INSTALLATION
1. Install fan shroud to radiator (Fig. 10).
2. Attach coolant pipe with hoses to fan shroud (Fig. 10).
3. Attach coolant hose at radiator (Fig. 10).
4. Install bottom radiator trim (Fig. 10).
5. Install charge air cooler along with cooling loop of the power steering, to radiator (Fig. 10).
6. Install radiator assembly into the rubber grommets (Fig. 9).
7. Install both right and left side radiator trim panels (Fig. 9).
8. Attach the transmission cooler lines (Fig. 9).
9. Attach coolant hose to the bottom right of the radiator (Fig. 9).
10. Attach both power steering hydraulic lines (Fig. 9).
11. Connect coolant level sensor electrical connector (Fig. 9).
12. Connect coolant hoses to the coolant reservoir, radiator and water pump (Fig. 9).
13. Attach air intake pipe at the body.
14. Attach charge air hose at air intake.
15. Attach charge air hose at turbocharger.
16. Install A/C condenser.
17. Install front bumper.
18. Install front end cross member.
19. Refill power steering to proper level.
20. Refill transmission to proper level.
21. Close radiator drain plug and refill the cooling system.
22. Recharge air conditioning.
23. Run engine until warm and check for leaks.