Radiator: Service and Repair

LEGEND
1 Radiator
2 V-belt
3 Guide Ring
4 Coolant Fan
5 Auxiliary Fan
6 Lock Carrier
7 Bolt/Screw
8 Upper Coolant Hose
9 Connector
10 Coolant Fan Control (FC) Thermal Switch
11 Lower Coolant Hose
12 Connection
13 O-ring
14 Retaining Clip

NOTE: During removal and installation procedures, refer to the component location illustration above and component notes below.

COMPONENT NOTES
Radiator (1)
- After replacing, replace all engine coolant.

Guide Ring (3)
- Note installation position.
- Secured on lock carrier -6- with clips.

Bolt/Screw (7)
- Tighten to: 10 Nm (7 ft. lbs.).

Upper Coolant Hose (8)
- From Thermostat Housing.

Coolant (FC) Thermal Switch (10)
- Tighten to: 35 Nm (26 ft. lbs.).
- For Coolant Fan -4-.
- Switching temperatures:

Stage 1:
ON: 92-97°C (197-206°F).
OFF: 84-91°C (183-195°F).

Stage 2:
ON: 99-105°C (210-221°F).
OFF: 91-98°C (195-208°F).

Lower Coolant Hose (11)
- To Thermostat Housing.

O-ring (13)
- Always replace.

Retaining Clip (14)
- Check to make sure clip is seated securely.

REMOVAL
1. Drain coolant.
2. Disconnect coolant hoses from radiator.
3. Disconnect connectors from coolant (FC) thermal switch and coolant fan.
4. Remove front bumper.
5. Remove headlights.
6. On models with A/c, proceed as follows:

NOTE:
- DO NOT open the A/C refrigerant circuit.
- To prevent damage to A/C condenser, and to the refrigerant lines and hoses, make sure that the lines and hoses are NOT stretched, kinked or bent

a. Disconnect Evaporative Emission (EVAP) Canister Purge Regulator valve with retaining ring from lower Air Cleaner (ACL) housing.
b. Remove (ACL) housing with Mass Air Flow (MAF) sensor.
c. Dismount A/C receiver/drier and allow to hang free.
d. Remove retaining clamp(s) from refrigerant lines.
e. Disconnect A/C condenser from radiator and pull forward as far as is possible.
f. Pull radiator out between A/C condenser and lock carrier.
g. Secure condenser to body so that refrigerant lines/hoses are not stressed.

7. On models less A/C, remove radiator mounting bolts and remove radiator toward the front.
8. On all models, remove V-belt from coolant fan and auxiliary fan pulleys.
9. Remove Coolant Fan and auxiliary fan from lock carrier.

INSTALLATION
- Install in reverse order of removal, noting the following:
a. Fill with coolant.
b. Ensure correct electrical connections and routing.
c. Check headlight adjustment and adjust if necessary.