| Removal and Installation Special Tool(s) | | Remover/Installer, Cooling Hose Clamp 303-397 (24-003) | General Equipment | | -
Using suitable cable ties, secure the air conditioning (A/C) condenser (if equipped) to the front panel. | | | -
Remove the right-hand headlamp assembly.
For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
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Remove the charge air cooler outlet pipe support bracket retaining bolt. | | | -
Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
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Remove the cooling fan motor and shroud.
For additional information, refer to: Cooling Fan Motor and Shroud (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
| 6. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Charge air cooler retaining bolts 8 - Coolant expansion tank to radiator hose 13 - Radiator upper insulators 7. To install, reverse the removal procedure. Removal Details Item 2 : Charge air cooler | | -
Detach the charge air cooler from the charge air cooler support brackets. | | | -
Using suitable cable ties, secure the charge air cooler to the front body panel. | Item 3 : Radiator lower hose retaining clamp | | -
Using the special tool, disconnect the radiator lower hose. | Item 5 : Radiator upper hose retaining clamp | | -
Using the special tool, disconnect the radiator upper hose. | Item 7 : Coolant expansion tank to radiator hose retaining clamp | | -
Using the special tool, disconnect the coolant expansion tank to radiator hose retaining clamp. | Item 9 : Radiator support bracket retaining bolts | | -
With the aid of another technician, support the radiator support bracket. | Item 10 : Radiator support bracket | | -
With the aid of another technician, support the radiator. | | | -
Disconnect the relay electrical connector (if equipped). | Item 11 : Radiator CAUTION:Care must be taken not to damage the cooling fins or tubes of the radiator and the A/C condenser when removing the radiator. Failure to follow this instruction may result in coolant leaks or engine overheat. Installation Details Item 12 : Radiator lower insulators CAUTION:Inspect the radiator lower insulators for signs of cracking, splitting or damage. Install new radiator lower insulators as necessary. Failure to follow this instruction may result in damage to the radiator. Item 11 : Radiator | | -
With the aid of another technician, install the radiator support bracket. - Install the 30 mm M8 bolts leaving 15 mm of thread exposed.
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Connect the relay electrical connector (if equipped). | |
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