ENGINE COOLING RADIATOR - R + R

Operation 1088B20 · ENGINE COOLING RADIATOR

2.2

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

1. Remove the sound insulation cover fastened to the engine by three pins.

1. Undo the bolts (1a) and remove the upper radiator crossmember guard (1b).

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

1. Undo the bolts fixing the lower radiator supports to the front suspension crossmember.

1. Loosen the band and disconnect the radiator upper coolant inlet hose, radiator side.

- Release the clips securing the electrical wiring to the front suspension crossmember.

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.

2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

3. Loosen the bands and remove the radiator coolant lower outlet hose.

1. Release the engine coolant radiator upper fastening clips.

- Lower the engine coolant radiator carefully forwards.

- Fasten the air conditioning condenser to the bodyshell.

2. Undo the bolts fixing the air conditioning condenser to the engine coolant radiator.

1. Loosen the band and disconnect the coolant return pipe to the engine coolant supply reservoir, radiator side.

1. Disconnect the electrical connection (1a) from the fans, then release the electrical wiring from the fastenings (1b) and move it aside.

1. Remove the engine coolant radiator complete with fans.

1. At the bench, undo the bolts (1a) and separate the engine coolant radiator (1b) from the fans and the duct (1c).

2. Remove the lower supports from the radiator.

Refitting

- Place the lower supports in their housings on the radiator.

- Join the engine coolant radiator with the fans and duct and secure them using the bolts.

- Place the engine coolant radiator complete with fans in its housing.

- Place the electrical wiring back in its housing, then secure it and connect the electrical connection to the fans.

- Connect the coolant return pipe to the engine coolant supply reservoir, radiator side and tighten the band.

- Tighten the bolts fixing the air conditioning condenser to the engine coolant radiator.

- Remove the temporary fastenings securing the air conditioning condenser to the bodyshell.

- Place the engine coolant radiator upper fastening clips in their housings.

- Place the lower coolant outlet hose from the radiator in its housing and secure it using the bands.

- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.

- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.

- Fasten the clips securing the electrical wiring to the front suspension crossmember.

- Connect the radiator upper coolant inlet hose, radiator side, and tighten the band.

- Tighten the bolts fixing the lower radiator supports to the front suspension crossmember to the recommended torque.

- Tighten the radiator coolant drain plug.

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

- Place the upper radiator crossmember guard back in its housing and secure it using the bolts.

- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.

- Connect the negative battery terminal.

Op. 0010T20 ENGINE COOLANT - CHANGE

- Remove the vehicle from the lift.

1.9 JTD 8v, 1.9 JTD 16v

Removing

- Position the vehicle on a lift.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 1048A42 SLEEVE FROM FLOW METER TO TURBO CHARGER AIR INLET PIPE - R + R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 1048B17 HEAT EXCHANGER AIR INLET HOSE - R.R.

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE

Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R

Op. 1088E11 FANS WITH SINGLE ENGINE DUCT - R+R

1. Undo the nut fixing the air conditioning system pipe to the air conditioning condenser.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Undo the bolts (2a) and remove the air conditioning system drier filter (2b) with built in pipe.

1. Undo the bolts (1a) and release the engine cooling radiator (1b) from the air conditioning condenser.

Refitting

- Fasten the engine cooling radiator to the air conditioning condenser and tighten the bolts.

- Place the air conditioning system drier filter with built in pipe in its housing and secure it using the bolts.

- Tighten the nut fixing the air conditioning system pipe to the air conditioning condenser to the recommended torque.

Op. 1088E11 FANS WITH SINGLE ENGINE DUCT - R+R

Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R

Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 1048B17 HEAT EXCHANGER AIR INLET HOSE - R.R.

Op. 1048A42 SLEEVE FROM FLOW METER TO TURBO CHARGER AIR INLET PIPE - R + R

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 7210E10 R.R. FRONT BUMPER

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

- Remove the vehicle from the lift.

2.2 · AUTOMATIC TRANSMISSION

Removing

- Position the vehicle on a lift.

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 0010T44 CHANGE AUTOMATIC TRANSMISSION FLUIDS

Op. 2130A27 DELIVERY AND RETURN DUPLEX PIPING OF AUTOMATIC GEARBOX OIL TO COOLING RADIATOR - R R

1. Remove the sound insulation cover fastened to the engine by three pins.

1. Undo the bolts (1a) and remove the upper radiator crossmember guard (1b).

1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

1. Undo the bolts fixing the lower radiator supports to the front suspension crossmember.

1. Loosen the band and disconnect the radiator upper coolant inlet hose, radiator side.

- Release the clips securing the electrical wiring to the front suspension crossmember.

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.

2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

3. Loosen the bands and remove the radiator coolant lower outlet hose.

1. Release the engine coolant radiator upper fastening clips.

- Lower the engine coolant radiator carefully forwards.

- Fasten the air conditioning condenser to the bodyshell.

2. Undo the bolts fixing the air conditioning condenser to the engine coolant radiator.

1. Loosen the band and disconnect the coolant return pipe to the engine coolant supply reservoir, radiator side.

1. Disconnect the electrical connection (1a) from the fans, then release the electrical wiring from the fastenings (1b) and move it aside.

1. Remove the engine coolant radiator complete with fans.

1. At the bench, undo the bolts (1a) and separate the engine coolant radiator (1b) from the fans and the duct (1c).

2. Remove the lower supports from the radiator.

Refitting

- Place the lower supports in their housings on the radiator.

- Join the engine coolant radiator with the fans and duct and secure them using the bolts.

- Place the engine coolant radiator complete with fans in its housing.

- Place the electrical wiring back in its housing, then secure it and connect the electrical connection to the fans.

- Connect the coolant return pipe to the engine coolant supply reservoir, radiator side and tighten the band.

- Tighten the bolts fixing the air conditioning condenser to the engine coolant radiator.

- Remove the temporary fastenings securing the air conditioning condenser to the bodyshell.

- Place the engine coolant radiator upper fastening clips in their housings.

- Refit the lower coolant outlet sleeve from the radiator and secure with the collars.

- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.

- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.

- Fasten the clips securing the electrical wiring to the front suspension crossmember.

- Connect the upper coolant inlet hose to the radiator, radiator side, and tighten the band.

- Tighten the bolts fixing the lower radiator supports to the front suspension crossmember to the recommended torque.

- Tighten the coolant drain plug to the radiator.

- Place the upper radiator crossmember guard back in its housing and secure it using the bolts.

- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.

Op. 2130A27 DELIVERY AND RETURN DUPLEX PIPING OF AUTOMATIC GEARBOX OIL TO COOLING RADIATOR - R R

Op. 0010T44 CHANGE AUTOMATIC TRANSMISSION FLUIDS

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

- Remove the vehicle from the lift.

2.4 JTD 20v

Removing

- Position the vehicle on a lift.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1084C40 AIR DUCT FOR ENGINE OIL COOLING RADIATOR - R.R.

1. Disconnect the electrical connection from the fans.

2. Disconnect the vacuum pipe from the turbocharger vane position actuator control solenoid valve.

1. Undo the nut (1a) and disconnect the air conditioning condenser inlet pipe (1b), air conditioning condenser side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

Undo the bolt (2a) and disconnect the pipe from the drier filter/accumulator to the air conditioning compressor (2b), drier filter/accumulator side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

1. Loosen the band and disconnect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side.

2. Undo the two bolts securing the intermediate rigid pipe between the heat exchanger and the throttle casing.

3. Loosen the band and disconnect the radiator upper coolant inlet hose, radiator side.

1. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side.

2. Disconnect the rapid connector for the lower coolant outlet hose from the radiator, radiator side.

1. Unscrew the nut (1a) and disconnect the automatic transmission fluid supply and return pipes to the cooling radiator (1b), automatic gearbox side.

Collect the automatic transmission fluid oil that comes out in a suitable container.

1. Position a hydraulic jack for supporting the engine cooling radiator assembly.

2. Undo the bolts securing the engine cooling radiator supports.

- Lower the hydraulic jack and remove the engine cooling radiator assembly.

1. Working at the bench, undo the bolt fixing the automatic transmission fluid cooling circuit thermostatic valve to the engine cooling radiator.

2. Undo the bolts (2a) and remove the fans and single engine cooling duct (2b).

1. Undo the nut (1a) and disconnect the air conditioning condenser outlet pipe (1b), air conditioning condenser side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Undo the bolts (2a) and remove the air conditioning condenser (2b).

1. Undo the bolts and remove the supercharging air/air heat exchanger (1b).

1. Undo the bolts (1a) and remove the automatic transmission hydraulic circuit cooling radiator (1b) complete with pipes.

1. Undo the bolts (1a) and remove the air conditioning drier filter/accumulator (1b).

Refitting

- Place the air conditioning drier filter/accumulator in its housing on the engine cooling radiator and secure it using the bolts.

- Place the automatic transmission hydraulic circuit cooling radiator complete with pipes in its housing and secure it using the bolts.

- Place the supercharging air/air heat exchanger in its housing and secure it using the bolts.

1. Place the air conditioning condenser (1a) in its housing and secure it using the bolts (1b).

2. Connect the outlet pipe from the air conditioning condenser (2a), air conditioning condenser side and tighten the nut (2b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid. Lubricate the connector threads using anti-freeze.

- Place the fans with the single engine cooling duct in their housings and secure them using the bolts.

- Tighten the bolt fixing the automatic transmission fluid cooling circuit thermostatic valve to the engine cooling radiator.

- Place the engine cooling radiator assembly in its housing using the hydraulic jack.

- Tighten the bolts securing the engine cooling radiator supports.

- Remove the hydraulic jack used for supporting the engine cooling radiator.

1. Connect the automatic transmission fluid supply and return pipes to the cooling radiator (1a), automatic gearbox side and tighten the nut (1b) to the recommended torque.

- Connect the rapid connector for the radiator lower coolant outlet hose, radiator side.

- Connect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side, and tighten the band.

- Connect the upper coolant inlet hose to the radiator, radiator side, and tighten the band.

- Tighten the two bolts securing the intermediate rigid pipe between the heat exchanger and the throttle casing.

- Connect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side and tighten the band.

1. Connect the pipe from the drier filter/accumulator to the air conditioning compressor (1a), drier filter/accumulator side and tighten the bolt (1b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid. Lubricate the connector threads using anti-freeze.

2. Connect the inlet pipe to the air conditioning condenser (2a), air conditioning condenser side and tighten the nut (2b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid. Lubricate the connector threads using anti-freeze.

- Connect the vacuum pipe to the turbocharger vane position actuator control solenoid valve.

- Connect the electrical connection to the fans.

Op. 1084C40 AIR DUCT FOR ENGINE OIL COOLING RADIATOR - R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T45 AUTOMATIC TRANSMISSION FLUID CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

- Remove the vehicle from the lift.

1.8

Removing

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 0010T20 ENGINE COOLANT - CHANGE

1. Undo the bolts fixing the lower radiator supports to the front suspension crossmember.

1. Loosen the band and disconnect the coolant outlet hose from the lower radiator connector.

2. Disconnect the electrical connection for the coolant temperature sensor on the radiator.

1. Loosen the band and disconnect the radiator coolant inlet hose, radiator side and remove it.

2. Loosen the band and disconnect the degassing pipe from the radiator.

1. Disconnect the resistor electrical connection.

2. Open the retaining clips and move the system water feed pipe aside.

1. Unscrew bolts (1a) securing the air conditioner condenser to the radiator (1b) and secure it to the body.

1. Remove the radiator with fan and coolant temperature sensor.

1. If necessary, unscrew bolts (1a) and remove fan (1b).

2. Undo the coolant temperature sensor and remove it.

Refitting

- Place the radiator complete with fan and coolant temperature sensor in position.

- Refit the air conditioner condenser and tighten the bolts securing it to the radiator.

- Refit the system water feed pipe in its seat and do up the retaining clips.

- Connect the resistor electrical connection.

- Connect the degassing pipe to the radiator and secure it using the band.

- Place the radiator coolant inlet hose in position and connect it to the radiator using the band.

- Connect the electrical connection for the coolant temperature sensor on the radiator.

- Connect the coolant outlet hose to the lower radiator connector and tighten the band.

- Tighten the bolts fixing the lower radiator supports to the front suspension crossmember.

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE