RADIATOR REMOVAL/INSTALLATION [MZ-CD 1.6]

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Warning

•  Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.

•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise 2.5 turns. Step back while the pressure escapes.

•  When you are sure all the pressure is gone, turn the cap using the cloth, and remove it.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6].)

4.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

5.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6].)

6.  Remove the fresh air duct (No.1, No.2), air cleaner and air hose component, charge air cooler hose (inlet and outlet), and charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

7.  Remove the cooling fan component. (See COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZ-CD 1.6].)

8.  Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6].)

12.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZ-CD 1.6].)

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1	Coolant reserve tank hose
2	Upper radiator hose
3	Lower radiator hose
4	Radiator mount (LH) (See Radiator Mount (LH) Removal Note.) (See Radiator Mount (LH) Installation Note.)
5	Radiator mount (RH) (See Radiator Mount (RH) Removal Note.)
6	Radiator (See Radiator Removal Note.)

Radiator Mount (LH) Removal Note

1.  While pressing the radiator mount tab in the direction of the arrow shown in the figure, lift the radiator mount.

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2.  Remove the radiator mount (LH).

Radiator Mount (RH) Removal Note

1.  Remove the radiator mount installation bolts.

2.  Release the tab by pressing them in the direction shown in the figure.

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3.  Remove the radiator mount (RH).

Radiator Removal Note

1.  Remove the shroud upper plate.

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2.  Remove the bolt which secure the condenser to the radiator.

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3.  Lift the radiator and remove it from the radiator installation holes on the shroud panel.

4.  Move the radiator and condenser to the engine side.

5.  Release the tab on the lower side of the radiator by pressing it in the direction shown in the figure.

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6.  Lift the condenser to remove it from the insertion areas on the radiator.

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7.  Set the condenser apart from the radiator.

8.  Remove the radiator from below the engine compartment.

Radiator Mount (LH) Installation Note

1.  Install the radiator mount so that the arrow on it is pointed toward the front of the vehicle.

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