Removal and Installation

1. Disconnect the negative battery cable.

WARNING: To avoid the possibility of scalding yourself, allow the engine to cool off.

Radiator Expansion Tank:

2. Loosen the radiator cap to the first detent, to vent the pressure, then remove the cap.

Lower Engine Cover:

3. Raise the vehicle and remove the bolts (504) and the lower engine cover [505].

Radiator Petcock:

4. Connect a hose (inner diameter 12 mm) to the radiator petcock [arrow]. Open the petcock [17] by turning in the counterclockwise direction and drain the radiator.

Engine Block Drain:

5. Connect a hose [1] (inner diameter 14 mm) to the engine block drain [2] (located on the R.H. side of the block near the oil pan at the rear). Open the drain by turning in the counterclockwise direction and drain the engine block.
6. Tighten the engine block drain.
TORQUE VALUE: 30 Nm (22 ft.lbs.)
7. Tighten the radiator petcock.
TORQUE VALUE: 1.5 Nm (1 ft.lb.)

Air Intake Boot:

8. Remove the screw for the air intake boot [338]. Remove the boot [339a] from the air cleaner.

Fan Shroud Assembly (Exploded View):

Removing The Fan Shroud:

9. Unclip the catches for the radiator shroud [1].

Ignition Distributor Bolts:

10. Remove the bolts [2] for the voltage distributor. Remove the distributor [4].

Tubing And Clip:

11. Squeeze the tubing clamp [174] as shown and relocate the coolant tube [178].

Moving The Fan Cowling Back Over The Fan:

12. Remove the clips [628] for the fan shroud.
13. Place the fan shroud [198] temporarily over the fan.

Rotating The Fan To Line Up The Retaining Slots:

14. Using an 8 mm socket and suitable ratchet, turn the fan until the hole in the pulley aligns with the hole in the water pump.

Special Tool For Loosening Fan Clutch Bolt:

15. Insert special tool #103 589 00 40 00 or suitable equivalent into the aligned holes.
16. Remove the fan clutch by turning the bolt in the counterclockwise direction.
TORQUE VALUE: 45 Nm (33 ft.lbs.)
17. Remove the fan and clutch assembly from the top.

Fan Clutch And Water Pump Pulleys:

18. Loosen, but do not remove, the bolts for the water pump and the fan pulleys [arrows].
TORQUE VALUE: 10 Nm (7 ft.lbs.)

Serpentine Belt Tensioner:

19. Loosen the belt tensioner bolt [211] 1/4 to 1/2 turn.
TORQUE VALUE: 70 Nm (52 ft.lbs.)
20. Turn the tension adjusting bolt [5] in the counterclockwise direction until the belt can be removed from the pulleys.

Fan Clutch And Water Pump Pulleys:

21. Remove the bolts from the pulleys [arrows] and remove the pulleys.

Air Conditioning Compressor Bolts:

22. Remove the A/C compressor bolts [424] and relocate the compressor.
TORQUE VALUE: 25 Nm (18.5 ft lbs).

Hydraulic Pump Bolts:

23. Remove the bolts [648 650] from the hydraulic pump.
TORQUE VALUE: 25 Nm (18.5 ft lbs).

Return Line:

24. Loosen the bolt [271] for the coolant return line (some vehicles have two bolts).
25. Remove the coolant return line [270] and relocate the line.
26. Remove the nut [225] and the bolt [218] for the hydraulic pump bracket.
TORQUE VALUE: 5 Nm (3.7 ft.lbs.)
27. Remove the radiator hoses [191 197] at the engine.
28. Disconnect the ignition cable from the hydraulic pump bracket and relocate the bracket.

Thermostat Housing:

29. Remove the bolts [246] and the thermostat housing [250].
TORQUE VALUE: 6 Nm (4.5 ft.lbs.)

By-Pass Hose And Hydraulic Line:

30. Loosen the by-pass hose clamps [267] and move the hose [266] to the left.
31. If the vehicle is equipped with self-leveling suspension, loosen the hose clamp [631] for the fluid line. Disconnect the line/hose connection [275 608] and plug the openings.

Water Pump Bolts:

32. Remove the water pump bolts [264 263] and remove the pump [265].
TORQUE VALUE: 25 Nm (18.5 ft lbs).

Exploded Water Pump Assembly:

33. Re-assemble in reverse order noting the following instructions:
^ Replace all seals, gaskets and o-rings.
^ Refer to BELT TENSION DATA for proper belt torque.
^ Install the thermostat with the ball valve at the highest point.

Engine Vent/Bleeder:

34. Remove the coolant vent plug, located on the cylinder head near the oil dipstick.
35. Add coolant to the reservoir until it leaks out of the vent. Tighten the vent.

Auxiliary Heater Bleeder:

36. If the vehicle is equipped with an auxiliary heater, remove the cap [635] on the bleeder [636].
37. Open the bleeder and add coolant to the reservoir until coolant leaks out of the bleeder.

NOTE: It may be necessary to repeat the previous bleeding steps (34 through 37) several times until all air is bled out of the system.

38. Start the engine and turn the heater on to the hottest position. Operate the engine until the thermostat opens.

NOTE: Install the reservoir cap when the engine temperature reaches 60 - 70° C.

39. Recheck the cooling system for leaks.