Do not begin any procedures until the engine has cooled down completely.
Removal
Models without power steering and crankcase
On vehicles with automatic transmission, the oil cooler is built into the engine cooling system circuit. To remove, pinch the oil hoses near the radiator. Close the fittings and pipes with plugs to prevent oil leakage. After installing the radiator, fill the transmission with oil (see Chapter Vehicle settings and routine maintenance).
1. Drain the coolant into a clean container by disconnecting the lower hose from the radiator.
2. On gasoline engines remove the air intake sleeve.
3. On x14XE and X16XE engines remove the additional air pump.
4. On diesel engine remove the fan motor together with the fan cover.
5. Disconnect the electrical wiring connector of the fan electric motor (1) and the thermal switch (2).
Connectors for wiring of electric fan motor (1) and D/V temperature (2)
6. Disconnect the upper radiator hose and the connecting hose going to the expansion tank.
Coolant hoses
7. Loosen the mounting bolts and detach the radiator bracket.
Radiator Bracket Mounting Bolts
8. Remove the radiator together with the fan upwards from the lower rubber supports.
9. If the radiator is being replaced, relocate the fan and thermal switch to the new radiator.
Features for cars with power steering and crankcase
1. Disconnect the wiring from the second thermal switch on the radiator.
2. Remove both thermal switches from the radiator.
3. Move the power steering fluid reservoir with the attached hoses to the side.
On 1.4L and 1.6L DOHC engines, carefully disconnect the high-pressure line from the power steering pump so that it can move slightly. To make room, tilt the high-pressure line toward the engine.
4. Remove the mounting bolts and detach the fan housing.
Examination
1. After removal from the vehicle, the radiator can be checked for signs of leaks, damage and violations of the internal permeability of the heat exchanger.
2. Insect and vegetation debris can be removed from the space between the heat exchanger plates by blowing with compressed air (don't forget to wear safety glasses!), or cleaning with a soft brush. Try not to bend the thin heat exchanger plates or cut your fingers on them. Before installation, the radiator should be flushed by spraying water into it from a garden hose (see Chapter Vehicle settings and routine maintenance).
3. Check the condition of the radiator rubber supports; if necessary, replace any faulty components.
4. Small leaks can be sealed with a suitable sealant (follow the product manufacturer's instructions). Any more complex repairs should be carried out only in a specialized workshop using the necessary equipment.
Installation
1. Installation is performed in the reverse order of dismantling the components. Please note the following points:
- Make sure the rubber pads on the lower radiator supports are installed correctly;
- Make sure all hoses are connected correctly and securely fastened with clamps;
- Finally, fill the cooling system (see Chapter Vehicle settings and routine maintenance) and inspection of its components for signs of developing leaks.
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