Cooling System: Service and Repair

Special Tools
998 5496

Note! Replacing radiators, refer to Radiator, Service and Repair.
Replacing Engine coolant temperature sensor, refer to Powertrain Management, Computers and Control Systems.

Check cooling system for leaks
Cooling system test pressurization





Use pressure tester 998 5496.
Connect tester to expansion tank cover.
Pump up the pressure and check for leaks.
- the pressure must be 150 kPa.
- the pressure in the system should be stable.

Note! Allow pressure to stabilize for a few minutes.

Drain coolant





Remove expansion tank cap.
Remove splashguard under the radiator.
Open the stopcock on the radiator. Thread a hose onto the stopcock to collect the coolant.
Close cock.

Disconnect the upper and lower radiator hoses





Remove the engine Coolant Fan (FC).
Disconnect the upper and lower radiator hoses from the radiator.
Turbo: Detach the oil cooler hoses from the right side of the radiator.
Automatic: Detach the oil cooler hoses from the left side of the radiator.

Remove the upper AC-condenser screws

Note! Applies to cars with Air Conditioning (A/C):





Remove the two upper screws holding the condenser to the radiator.
Hang the radiator as illustrated with string or similar.

Remove the lower AC-condenser screws





Remove the two lower screws holding the condenser to the radiator.

Remove the radiator
Remove two radiator retaining screws.





Caution: Hold the radiator so it is not damaged.

Install the radiator





Tighten the radiator to 30 Nm (22.13 ft. lbs.).
Install the two lower screws holding the AC condenser loosely.

Tighten clamps the radiator/Air Conditioning (A/C) condenser





Install the two upper screws for radiator/condenser.

Install the radiator hoses and engine Cooling Fan (FC)





Install the upper and lower radiator hoses.
Install the engine Cooling Fan (FC).
Raise the car and tighten the lower screws holding the AC condenser to the radiator.
Reinstall the splash guards.

Top up coolant





Fill the cooling system through expansion tank.
The total coolant capacity is approximately 7.2 liters (1.9 US gallons).
Run the engine to operating temperature and top up coolant if necessary.
Check for leaks.

Coolant-temperature sensor location





The sensor is located in the thermostat housing.
The sensor gives a signal to both the engine management system and the combined instrument panel temperature gauge.