Dismantling
1. Disconnect "negative" battery terminal.
2. Remove the soundproof engine cover (if installed).
ENGINE - Td4, Intake and Exhaust Camshafts, Engine Soundproofing, Models up to May 2002.
3. Models without air conditioning: Remove the bumper apron.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
4. Models without air conditioning system: Remove 4 nuts and 4 bolts of the bumper frame and remove the frame.
5. Models without A/C system: Remove the aftercooler.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, Intercooler air.
6. Air Conditioning Models: Remove the condenser from the vehicle.
AIR CONDITIONING SYSTEM, A/C compressor drive belt - for models with Td4 engine, Condenser.
7. Drain the engine coolant.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
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. Turn away 4 bolts of fastening of a casing of the fan to a radiator.
11. Turn away 4 self-tapping screws of fastening of racks of a radiator to a body, release racks and remove them.
12. 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.
13. Remove from a radiator 2 spring clips.
14. Release a radiator from the bottom support and remove it from the car.
15. Remove 4 rubber pads from the radiator.
Installation
1. Install the rubber pads on the radiator.
2. Align the heatsink with the fan shroud and put on the spring clips.
3. Install the radiator so that it pops into the sockets of the supports on the body.
4. Install the upper radiator supports into the cross member of the radiator frame.
5. Screw in the bolts securing the fan shroud to the radiator and tighten them to 5 Nm.
6. Attach a hose to a broad tank and fix it with a collar.
7. Attach the top and bottom hoses to a radiator and fix them collars.
8. 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.
9. Non-A/C Models: Install an aftercooler.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, Intercooler air.
10. Establish racks of a radiator and fix them self-tapping screws.
11. Models without air conditioning system: Install the bumper frame, install and tighten the 4 nuts and bolts securing the frame to the body.
12. Models without air conditioning: Install the bumper apron.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
13. Add coolant to the cooling system.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
14. Install the acoustic cover (if installed).
ENGINE - Td4, Intake and Exhaust Camshafts, Engine Soundproofing, Models up to May 2002.
15. Attach "negative" battery terminal.
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