Dismantling
1. Disconnect "negative" battery terminal.
2. Remove a noise-insulating casing of the engine.
KV6 ENGINE - MODIFICATION K, Camshafts of the left cylinder head, Noise-insulating casing of the engine.
3. Drain the engine coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
4. Models without A/C system: Remove the bumper apron.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
5. Models without A/C: Remove the 2 bolts securing the power steering cooler to the bumper frame.
6. Models without air conditioning system: Remove 4 nuts and 4 bolts of the bumper frame and remove the frame.
7. Models with air conditioning system: Remove the condenser from the vehicle.
AIR CONDITIONING SYSTEM, A/C compressor drive belt - for models with Td4 engine, Condenser.
8. Loosen the clamps and remove the upper and lower cooling system hoses.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
9. Loosen the clamp and remove the expansion tank hose from the radiator.
10. If installed: Remove 2 bolts and 4 self-tapping screws securing the right and left radiator struts and remove the struts.
11. Turn out screws of fastening of a radiator in gathering from the top cross-beam of a frame of a radiator. Pull the top of the radiator forward.
12. Turn away 4 bolts of fastening of a casing of the fan to a radiator.
13. Remove from a radiator 2 spring clips.
14. Release a radiator from the bottom support and remove it from the car.
15. Turn away the top arms of a radiator.
16. Remove 4 rubber pads from the radiator.
Installation
1. Install the rubber pads on the radiator.
2. Install the upper radiator brackets.
3. Install the fan assembly with the electric motor on the radiator, screw in the screws and tighten them with a torque of 5 Nm.
4. Clip the fan shroud onto the heatsink.
5. Install the radiator so that it falls into the sockets of the supports on the body.
6. Install the upper radiator supports into the cross member of the radiator frame.
7. If installed: Install the left and right radiator struts and secure them with self-tapping screws, screw in the upper bolts and tighten them to a torque of 5 Nm.
8. Attach a hose to a broad tank and fix it with a collar.
9. Attach the top and bottom hoses to a radiator and fix them collars.
10. Models with air conditioning system: Install the condenser on the vehicle.
AIR CONDITIONING SYSTEM, A/C compressor drive belt - for models with Td4 engine, Condenser.
11. Non-A/C Models: Install the bumper frame and install and tighten the 4 nuts and bolts securing the frame to the body.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
12. Models without air conditioning system: Install the power steering cooler and tighten the mounting bolts to 8 Nm.
13. Models without air conditioning: Install the bumper apron.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
14. Fill the engine with coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
15. Reinstall the acoustic cover.
KV6 ENGINE - MODIFICATION K, Camshafts of the left cylinder head, Noise-insulating casing of the engine.
16. Attach "negative" battery terminal.
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