Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the engine soundproofing cover.
ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Soundproofing engine casing.
3. Drain the coolant from the engine.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Draining coolant, flushing and filling the system.
4. Models without air conditioning: Remove the bumper cover.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
5. Models without air conditioning: Remove the 2 bolts securing the power steering radiator to the bumper frame.
6. Models without air conditioning: Remove the 4 nuts and 4 bolts securing the bumper frame and remove the frame.
7. Models with air conditioning: Remove the condenser from the vehicle.
AIR CONDITIONING SYSTEM, Air conditioning compressor drive belt - for models with Td4 engine, Condenser.
8. Loosen the clamps and remove the upper and lower coolant hoses.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
9. Loosen the clamp and remove the expansion tank hose from the radiator.
10. If installed: Unscrew the 2 bolts and 4 screws securing the right and left radiator struts and remove the struts.
11. Remove the radiator assembly mounting screws from the upper radiator frame crossmember. Move the upper part of the radiator forward.
12. Unscrew the 4 bolts securing the fan casing to the radiator.
13. Remove 2 spring clips from the radiator.
14. Release the radiator from the lower supports and remove it from the vehicle.
15. Unscrew the upper radiator brackets.
16. Remove 4 rubber cushions from the radiator.
Installation
1. Install 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 to a torque of 5 Nm.
4. Secure the fan shroud to the radiator with spring clips.
5. Install the radiator so that it fits into the support sockets on the body.
6. Install the upper radiator supports into the radiator frame cross member.
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. Connect the hose to the expansion tank and secure it with a clamp.
9. Attach the upper and lower hoses to the radiator and secure them with clamps.
10. Models with air conditioning: Install the condenser on the vehicle.
AIR CONDITIONING SYSTEM, Air conditioning compressor drive belt - for models with Td4 engine, Condenser.
11. Models without air conditioning: Install the bumper frame, fit and tighten the 4 nuts and bolts securing the frame to the body.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
12. Models without air conditioning: Install the power steering radiator and tighten the mounting bolts to 8 Nm.
13. Models without air conditioning: Install the bumper apron.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
14. Fill the engine with coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Draining coolant, flushing and filling the system.
15. Install the soundproofing casing in place.
ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Soundproofing engine casing.
16. Connect the negative battery terminal.
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