Procedures

Special Tool:
- Pressure Tester tool No. 998 5496, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to Service and Repair. Tools For Engine Service and Repair

Procedures
- Radiator, replacement: steps 1 through 9
- Engine coolant-temperature (ECT) sensor: step 10





Cooling System, Check For Leaks
Test pressure of cooling system
- Use pressure tester 998 5496.
- Connect tester to expansion tank cap.
- Pump up pressure and check for leaks.
pressure should be 150 kPa (22.5 psi).
pressure in the system should be stable.

NOTE: Allow the pressure to stabilize for a few minutes.





1. Drain coolant:
- Remove expansion tank cap.
- Remove guard under radiator.
- Open radiator drain cock. Collect coolant with a hose on the drain cock.
- Close drain cock.





2. Detach the upper and lower radiator hoses:
- Remove the engine coolant fan FC.
- Detach the upper and lower engine radiator hoses
- Turbo: Detach the oil cooler hoses from the right side of the oil cooler.
- Automatic: Detach the oil cooler hoses from the left side of the oil cooler.

Cars Fitted With A/C:





3. Remove upper A/C-condenser bolts
- Remove two upper bolts holding condenser to radiator.
- Hang up radiator with a cord as illustrates.





4. Remove lower A/C-condenser screws
- Remove two lower bolts holding condenser to radiator.





5. Disconnect radiator:
- Remove two bolts holding radiator.

CAUTION: Hold radiator to avoid damaging it.





6. Install radiator:
- Tighten radiator to 30 Nm (18 ft lb).
- Finger tighten two lower bolts holding A/C-condenser.





7. Tighten radiator/A/C-condenser:
- Install two upper screws for radiator/condenser.





8. Install radiator hoses and engine coolant fan:
- Install upper and lower radiator hoses.
- Install engine cooling fan.
- Raise car and tighten lower screws holding AC condenser to radiator.
- Reinstall splashguard.





9. Fill coolant:
- Fill cooling system through expansion tank.
- Total coolant capacity is about 7.2 l (7.6 US qt.).
- Run engine warm and top up if necessary.
- Check for leaks.

Engine Coolant Temperature Sensor





10. Location engine coolant-temperature sensor:
- The sensor is located in the thermostat housing.
- The sensor sends a signal to both the ignition and fuel systems and the combined instrument temperature gauge.