Radiator

/ 9-3 (9440) / 2003 / 2. Engine / 4-cylinder diesel / Cooling system / Adjustment/replacement / Radiator

To remove

Warning The cooling system is under pressure. Hot coolant and steam can escape. - Open the cap slowly to release the pressure. - Carelessness can cause eye and burn injuries

1.	Remove the expansion tank cap to release the pressure.

2.	Remove the battery cover.

3.	Remove the upper engine cover.

4.	Remove the washer fluid filler pipe.

5.	Remove the battery cooler pipe.

6.	Remove the power steering fluid reservoir and bracket from the battery box and move them aside.

7.	Remove the A/C pipe from the radiator member.

8.	Remove the upper radiator crossmember .

9.	Disconnect the charge air hose from the throttle body.

10.	Remove the upper charge air pipe mounting from the fan cowling (right-hand side).

11.	Disconnect the charge air hose from the charge air pipe on the camshaft cover.

12.	Slacken the upper bolt holding the charge air pipe to the side of the radiator (right-hand side).

13.	Raise the car.

14.	Remove the front spoiler shield .

15.	Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant.

16.	Disconnect the charge air hose from the charge air pipe (left-hand side).

17.	Remove the lower bolt from the charge air pipe mounting on the radiator (right-hand side).

18.	Remove the bolts securing the receiver drier to the radiator.

19.	Remove the lower cover from radiator assembly.

20.	Lower the car.

21.	Remove the upper radiator mountings from the body.

22.	Remove the bleeder hose from the radiator.

23.	Remove the bolts securing the fan and lift the fan cowling out off its mountings.

24.	Remove the cover from over the radiator assembly.

25.	Remove the radiator bolts from the charge air cooler.

26.	Fit 83 95 212 Strap between the radiator and charge air cooler. Raise the charge air cooler slightly to detach it from the radiator and move the radiator assembly forward and secure it in position with the strap.

27.	Remove the upper coolant hose.

28.	Raise the car.

29.	Remove the left-hand radiator mounting from the subframe.

30.	Remove the lower coolant hose.

31.	Remove the other radiator mounting from the subframe and remove the radiator.

32.	If changing the radiator: Transfer the upper charge air pipe mountings and upper coolant hose to the new radiator.

To fit

1.	Check that the drain cock is closed.

2.	Lift up the radiator. Align the mountings with the subframe and thread the bolts.

3.	Adjust the radiator in the mountings on the subframe and tighten the bolts.

4.	Fit the lower coolant hose.

5.	Fit the receiver drier to the radiator.

6.	Fit the lower bolt to the mounting between the radiator and charge air pipe.

7.	Lower the car.

8.	Slacken the strap.

9.	Fit the condenser and charge air cooler to the radiator.

10.	Fit the upper coolant hose.

11.	Fit the bolts holding the radiator and charge air cooler together.

12.	Fit the upper bolt securing the charge air pipe to the radiator (right-hand side).

13.	Fit the fan cowling. Important Make sure the lower catches of the fan cowling go into their mountings. Otherwise, there is a risk that the cooling system could be damaged.

14.	Fit the upper cover to the radiator and charge air cooler.

15.	Fit the upper radiator mountings to the body.

16.	Connect the radiator bleeder hose.

17.	Fit the hose between the charge air pipe and throttle body.

18.	Fit the radiator member .

19.	Make sure the A/C pipe is held in place by clips on the right-hand side and fit the A/C pipe to the radiator member.

20.	Fit the charge air hose to the charge air pipe on the camshaft cover.

21.	Raise the car.

22.	Fit the lower cover to the radiator assembly.

23.	Connect the charge air hose to the charge air pipe (left-hand side).

24.	Fit the front spoiler shield .

25.	Lower the car.

26.	Replace the upper engine cover.

27.	Fit the power steering fluid reservoir and bracket to the battery box.

28.	Fit the battery cooler pipe.

29.	Fit the washer fluid filler pipe.

30.	Fit the battery cover.

31.	Fill the system with coolant and fit the expansion tank cap.

32.	Start the engine and fill the cooling system to about 20 mm above the mark on the expansion tank.

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