Radiator: Service and Repair

REMOVAL
1. Loosen the expansion tank pressure cap and raise the car.
2. Remove the center air deflector, place a drip tray under the radiator and open the radiator drain plug.
3. Remove the lower two retaining bolts from the condenser (A/C).
4. Lower the car and detach the upper coolant hose. Remove the air intake pipe for the air cleaner.
5. Remove the upper retaining bolts on the condenser (A/C).
6. Unplug the cables to the boost pressure control valve and remove it from the bracket on the fan cowling turbo models only.
7. Unplug the electrical connections from the radiator fan and the thermostatic switch.





8. Detach the oil cooler and move it to one side. The lower two bolts on the oil cooler only need to be loosened, not removed. Remove the breather hose and the lower coolant hose from the radiator.
9. Remove the ignition coil mounting.
10. Disconnect, plug and move aside the transmission fluid hoses automatic transmissions only.
11. Remove the bolt securing the radiator to the radiator crossmember. Lift the radiator out of its rubber mountings.





INSTALLATION
1. Place the oil cooler in front of the compressor make sure that the pipe is in position before the cooler is put down as it cannot be installed later.
2. Place the radiator in the rubber mountings and push it down.
3. Install the upper radiator bolt in the center mounting in the radiator crossmember.
4. Connect the transmission fluid hoses automatic transmissions only. Tightening torque 25 Nm (18.5 ft. lbs.).
5. Install the oil cooler and the breather hose to the radiator. Install the lower coolant hose.





6. Install the boost pressure control valve turbo models only. Install the ignition coil mounting on the radiator crossmember.
7. Connect the electrical cables to the radiator fan and to the boost pressure control valve turbo models only and secure the cables. Secure the cable to the thermostatic switch.
8. Install the upper coolant hose to the radiator.
9. Do up the upper securing bolts for the condenser (A/C).
10. Connect the air intake pipe for the air cleaner and raise the car. Do up the lower two retaining bolts for the condenser (A/C).
11. Install the drain plug and tighten it by hand. Install the center air deflector, lower the car and test pressurize the system.
12. Top up the coolant in the expansion tank.
13. Install the pressure cap and run the engine until warm. Fill up as necessary.