Attention! Any work on maintenance or repair of the cooling system should be carried out on a cold engine! See also the warnings at the beginning of Section 2.
Based on the operation to remove the radiator on models with Z16XE / Z18XE engines without air conditioning. For other engines, only additional operations or features of this procedure.
Engine Z16XE/Z18XE (without air conditioning)
Removing
1. Disconnect the battery (see chapter 5).
2. Remove the engine cover (see chapter 2), front bumper (see chapter 11) and drain the coolant (see Section 3).
3. Loosen the bolts of the lower radiator holder - the holder itself does not need to be removed.
4. Release the left and right upper spring supports (see resist. illustration) out of the mounting points and carefully tilt the heatsink forward. Turn out 2 bolts of fastening of the condenser to assembly of a radiator and tie it up with a wire to body elements.
7.4 Upper spring supports (1) radiator - the arrows indicate the bolts of the condenser to the radiator: 2. Capacitor
5. Loosen the fastening clamps, disconnect the overflow hose from the expansion tank, the upper radiator hose from the thermostat housing and the lower cooling system hose from the radiator.
Note: When removing the lower hose, some coolant may leak out; substitute a suitable container.
6. Disconnect the connector (see illustration 6.4) Wiring for cooling fan control module.
7.7 Lower holders (1) engine cooling radiator
7. Tilt the radiator back and unscrew the mounting bolts (see resist. illustration) lower radiator brackets.
8. Carefully remove the radiator from the bottom of the engine compartment. After loosening the fastening clamps, remove the overflow and upper hoses of the cooling system from the radiator.
9. If necessary, remove the fan housing from the heatsink (see Section 6) top springs.
Examination
10. Once removed from the vehicle, the radiator can be inspected for signs of leaks, damage, or abnormalities in the internal patency of the heat exchanger.
11. The remains of insects and vegetation can be removed from the space between the heat exchanger plates by blowing with compressed air (don't forget to wear safety goggles!), or scrubbing with a soft brush. Take care not to bend the thin heat exchanger plates or cut your fingers on them. If necessary, before installation, the radiator can be flushed by introducing water from a garden hose into the interior (see Section 5).
12. Check up a condition of rubber support of a radiator, in case of need make replacement of the failed components.
13. Sources of small leaks can be sealed with a suitable sealant (act in accordance with the manufacturer's instructions). Any more complex repairs should be carried out only in a specialized workshop using the necessary equipment.
Installation
14. If the radiator is being replaced, reinstall all attachments from the old one on the new radiator and install the fan shroud.
15. Installation is carried out in the reverse order to the dismantling of the components. After completion of work, fill the cooling system (see Section 3), bleed the air and make sure the system is tight.
Features of the Z19DT engine (H)
16. Loosen the 2 clamps securing the top air intake pipe.
17. Release the vacuum line from the holders on the fan housing.
18. Turn out a bolt of fastening of the bottom branch pipe of supercharged air.
19. Remove the crankcase protection (see chapter 2).
20. Remove headlight (see chapter 12).
21. Turn out 1 top and 2 bottom bolts of fastening of the case of an inlet air duct.
22. Disconnect the receiver-drier and tie it with wire to the body elements.
23. Turn out 2 bolts and separate a charge air cooler (intercooler).
Features of Y20DTH/Y22DTR engines
24. Remove the battery guard covers
25. Press the latches and disconnect the connector (see resist. illustration) cooling system control module wiring.
7.25 Connector (1) wiring of the cooling system control module - the arrow indicates the direction of depressing the latch (motors Y20DTH/Y22DTR)
26. Turn out a fixing bolt (see resist. illustration) and disconnect the pipe from the charge air cooler (intercooler).
7.26 Remove the fixing bolt (1) and disconnect the pipe from the charge air cooler (motors Y20DTH/Y22DTR)
27. Loosen 2 clamps and remove the hose (see resist. illustration) turbocharger.
7.27 Hose (1) turbocharger (motors Y20DTH/Y22DTR)
28. Loosen the 2 clamps and remove the connecting hose (see resist. illustration) intake air path. Turn out 2 fixing bolts and remove a branch pipe of an inlet air path from a turbocharger.
7.28 Connecting hose (2) and pipe (1) turbocharger (motors Y20DTH/Y22DTR)
29. Loosen the clamps and remove the second connecting hose (see resist. illustration) intercooler. Unscrew the lower fixing bolt, separate it from the intercooler and set aside the intake air duct pipe.
7.29 Intercooler connecting hose (motors Y20DTH/Y22DTR)
30. Disconnect the lower hose of the cooling system from the radiator.
31. Turn out bolts of fastening of the bottom holders of a radiator and carefully with the help of the assistant take assembly of a radiator from an impellent compartment downwards. If necessary, remove the mounting bolts and remove the intercooler from the radiator.
32. Before installing the radiator, carefully place the intercooler in place and tighten the bolts to the required torque (see specs).
33. Further installation is carried out in the reverse order of removal.
7.33 When installing the intake air path hoses, it is necessary to align the protrusions of the pipes with the grooves on the hoses (motors Y20DTH/Y22DTR)
Attention! When installing the connecting hoses for the intake air duct, make sure that the protrusions (see resist. illustration) on the nozzles were combined with the grooves on the hoses!
Features of the Z20NET engine
34. Remove a hose and a branch pipe of an inlet path of charge air.
35. Screw off the intercooler (see resist. illustration).
7.35 Bolts (indicated by arrows) intercooler mounts
36. Remove the covers of the protective casing of the battery, having previously disconnected the hose of the cooling system.-
Features of Z22SE/ Z22YH engines
37. The difference lies only in the tightening force of the bolts of the lower holders (see specs).
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