Radiator: Service and Repair

Radiator Assembly - Up to MY03

Service Repair No - 16.40.01

Remove

1. Remove fixings and remove battery cover.
2. Disconnect negative battery cable.
3. Drain cooling system.
4. Remove upper fan cowl.





5. Remove 2 screws securing lowe half of fn cowl and remove cowl.
6. Release clip and disconnect radiator top hose from radiator.
7. Release clip and disconnect bleed hose from radiator.
8. Remove front grille.





9. Disconnect multiplug of gearbox oil temperature sensor. Remove clips and remove air deflectors front front panel.





10. Remove horns.
11. Move sound deading from behind each horn aside.





12. Remove 2 bolts securing radiator LH and RH upper mounting brackets to body panel and remove brackets.
13. Remove 4 screws securing air conditioning condenser LH and RH upper mounting brackets to condenser.
14. Remove brackets with rubber mounts from radiator extension brackets.
15. Position absorbent cloth under gearbox cooler hose connection to collect spillage.





16. Release quick release connector and disconnect gearbox fluid cooler pipe from gearbox fluid cooler.

CAUTION: Always fit plugs to open connections to prevent contamination.

17. Remove RH and LH radiator extension bracket air deflector securing bolts and remove air deflectors.
18. Remove 2 bolts securing radiator RH and LH upper mounting bracket to body panel and remove brackets.
19. Move gearbox oil cooler aside.
20. Move engine oil cooler aside.
21. Position suitable protection between radiator and cooling fan.
22. Release radiator from lower mountings and remove from vehicle.





23. Remove 2 captive nuts from radiator.
24. Remove sealing strip from bottom of radiator.
25. Remove 2 cowl retaining clips from radiator.
26. Remove rubber mountings from radiator.

Refit

1. Fit rubber mountings to radiator.
2. Fit cowl retaining clips to radiator.
3. Fit sealing strip to radiator.
4. Fit captive nuts to radiator.
5. Fit radiator and engage lower mountings in chassis.
6. Fit engine oil cooler.
7. Fit gearbox oil cooler.
8. Fit RH and LH radiator air deflectors and refit brackets.
9. Fit brackets with rubber mounts to radiator extension brackets.
10. Fit RH and LH upper mounting brackets to condenser.
11. Fit upper mounting brackets to front panel.
12. Remove protection from between cooling fan and radiator.
13. Ensure connections are clean and fit hose to gearbox oil cooler.
14. Wipe up any spillage and discard absorbent material.
15. Fit sound deadening back in position.
16. Fit horns.
17. Connect multiplug of gearbox oil temperature sensor.
18. Fit air deflectors to front panel.
19. Fit front grille.
20. Connect radiator bleed hose.
21. Connect top and bottom radiator hoses and secure.
22. Fit lower half of fan cowl and secure with screws.
23. Fit and secure upper fan cowl.
24. Connect negative battery cable.
25. Fit and secure battery cover.
26. Fill and bleed cooling system.
27. Check and top up gearbox oil.