Replacing the cooling system radiator

The radiator must be replaced if a coolant leak is detected in it.

In a workshop with special equipment, the radiator can be checked and repaired.

WARNING: Remove the radiator only when the engine is cold.

NOTE: For clarity, work is shown on a vehicle with the front bumper removed.

1. Disconnect a wire from the minus plug of the storage battery.

2. Drain the coolant (see Coolant Change).

3. Remove the mudguard and crankcase protection (see Removal and installation of mudguard and crankcase protection).



4. Squeeze the clamps of the wiring harness block of the electric fan control unit and disconnect the block from the block outputs.



5. Disconnect the coolant outlet hose from the radiator.




6. Similarly disconnect from a branch pipe of a radiator the top inlet hose.



7. Turn out the top fastenings of a radiator..



8….and remove them.



9. Turn out on two bolts of fastening of a cross-section of a front end and remove a cross-section in gathering with a radiator and the electrofan. If necessary, remove the radiator from the cross member.

NOTE: This is how the cross member mounting bolts are located.

10. Rinse the outside of the radiator with a jet of water and dry. If cracks appear on the plastic tanks of the radiator, replace the radiator.

11. Check the tightness of the radiator, for which plug its pipes, supply air to the radiator at a pressure of 0.1 MPa (1 kgf/cm²) and immerse in a container of water for at least 30 seconds. Leakage of the radiator is determined by the outgoing air bubbles. If the radiator does not fit into the container as a whole, check it sequentially from all sides.

12. Install the radiator and all removed parts in the reverse order of removal.

USEFUL ADVICE: In order to further eliminate the possibility of coolant leakage, before installing the hoses, lubricate the radiator pipes with a thin layer of silicone sealant.

13. Fill in coolant and remove air pockets from the cooling system (see Coolant Change).