RADIATOR REMOVAL/INSTALLATION [MZR-CD 2.2]

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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 to the first stop. Step back while the pressure escapes.
•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1.  Disconnect the negative battery cable.

2.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the dipstick.

5.  Remove the boost sensor. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

6.  Remove the air cleaner and charge air cooler air hose (inlet and outlet). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.  Remove the cooling fan component. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the radiator grille. (See RADIATOR GRILLE REMOVAL/INSTALLATION.)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

13.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD 2.2].)

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1
Lower radiator hose
2
Upper mount rubber bracket
(See Upper Mount Rubber Bracket Removal Note.)
3
Upper mount rubber
4
Radiator
(See Radiator Removal Note.)


Upper Mount Rubber Bracket Removal Note

Caution
•  To prevent damage to the upper mount rubber bracket tab, do not apply excessive force.
Note
•  The upper mount rubber bracket can be easily removed by pressing down the upper mount rubber bracket tab using one hand and pressing the notch area downward using the other hand.

1.  While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the figure, press the upper mount rubber bracket toward the vehicle front.

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2.  Remove the upper mount rubber bracket.


Radiator Removal Note

1.  Remove the four bolts which secure the condenser to the radiator and set the condenser apart from the radiator.

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2.  Remove the radiator from above the engine compartment.