Caution! Remove the radiator and expansion tank when the engine is cold.
Caution! Avoid contact with coolant on clothing or vehicle paintwork. Otherwise, rinse the surface with plenty of water.
Caution! Collect and dispose of drained coolant.
Replacing the radiator
Turn off the ignition and disconnect the ground wire from the battery.
Drain the coolant.
On vehicles manufactured before 2001, remove the A/C condenser fan shroud mounting bolts and lift it away from the radiator.
On vehicles produced since 2001, remove the radiator grille, protective panel and hood latch.
Disconnect the upper and lower cooling system hoses from the radiator.
Disconnect the hose from the radiator that connects it to the expansion tank.
Remove the radiator fans.
Figure 4.9. Hose connections to the heat exchanger for cooling the transmission fluid
On vehicles with an automatic transmission, disconnect the transmission fluid cooler hoses from the heat exchanger (figure 4.9). Before disconnecting the hoses, place a container to collect any leaking oil.
Figure 4.10. Loosening the radiator mounting bolt on vehicles manufactured before 2001
Figure 4.11. Location of radiator mounting bolts on vehicles produced since 2001
Remove the radiator mounting bolts from the front cross panel (figure 4.10, 4.11).
Lift the radiator and remove it from the vehicle.
If the radiator is removed due to reduced flow capacity, flush it with a jet of water in both directions and blow it out from the outside with compressed air.
If your radiator is leaking, do not attempt to weld or solder the leak, as this will damage the plastic parts of the radiator.
A minor radiator leak can be repaired with radiator sealant.
Check the condition of the lower radiator rubber mounts and replace them if necessary.
Install the radiator in the reverse order of removal, taking into account the following.
Fill with coolant.
On vehicles with automatic transmission, check the transmission fluid level.
Start the engine and check for leaks.
Replacing the expansion tank
On most models, removing the reservoir is very easy: just pull it out of the fender bracket.
Drain the coolant from the reservoir. Rinse the tank and inspect it for cracks and abrasions. If there is any damage, replace the expansion tank.
Install the expansion tank in the reverse order of removal.