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Radiator Replacement — LDE, LLU, and LUJ with AT

Removal Procedure
  1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  3. Drain coolant fluid. Refer to Cooling System Draining and Filling .
  4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  5. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  6. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  7. Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement .
  8. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement : Manual Gearbox .
  9. Remove the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
  10. Remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement : 2.0L Diesel LNP → 2.0L Diesel LLW .
  11. Remove the transmission fluid cooler outlet pipe from the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement : 2.0L Diesel LNP → 2.0L Diesel LLW .
  12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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  13. Remove the air conditioning evaporator hose (3) from the condenser.
  14. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (2).
  15. Disconnect the engine coolant temperature sensor wiring harness plug (1).
  16. Lower the vehicle.

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  17. Remove the air conditioning compressor and condenser hose nut (1).
  18. Remove the air conditioning compressor and condenser hose (2).
  19. Unclip the engine coolant fan shroud from the radiator and hang it aside, using cable straps.
  20. Secure the radiator assembly with 2 straps.

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  21. Remove the 4 radiator lower bracket bolts (1).
  22. Remove the 2 lower radiator brackets (2).

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    Note: A second technician is required.

    Note: Do not remove the engine cooling fan shroud (1).

  23. Remove the radiator assembly (2).

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  24. Remove the transmission fluid auxiliary cooler pipe bolt (3).
  25. Unclip the 2 transmission fluid cooler pipes (2) from the transmission fluid cooler pipe bracket.
  26. Unclip the transmission fluid cooler (1) from the radiator.
  27. Unclip the transmission fluid cooler pipe bracket from the radiator.
  28. Unclip the charge air cooler along with the AC condenser from the radiator.

Installation Procedure
  1. Clip the charge air cooler along with the AC condenser to the radiator.
  2. Clip the transmission fluid cooler pipe bracket to the radiator.

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  3. Clip the transmission fluid cooler (1) to the radiator.
  4. Clip the 2 transmission fluid cooler pipes (2) to the transmission fluid cooler pipe bracket.
  5. Install the transmission fluid auxiliary cooler pipe bolt (3) and tighten.

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    Note: A second technician is required.

  6. Install the radiator assembly (2) and secure with 2 straps.

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  7. Install the 2 lower radiator brackets (2).

    8. Caution: Refer to Fastener Caution in the Preface section.

  8. Install the 4 radiator lower bracket bolts (1) and tighten to 22 N·m (16 lb ft).
  9. Clip in the engine coolant fan shroud to the radiator.

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  10. Install the air conditioning compressor and condenser hose (2). Use a NEW seal ring.

    11. Install the air conditioning compressor and condenser hose nut (1) and tighten to 19 N·m(14 lb ft).

  11. Raise the vehicle.

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  12. Install the air conditioning evaporator hose (3) to the condenser. Use a NEW seal ring.
  13. Tighten the air conditioning evaporator hose nut to 19 N·m(14 lb ft).
  14. Connect the air conditioning refrigerant pressure sensor wiring harness plug (2).
  15. Connect the engine coolant temperature sensor wiring harness plug (1).
  16. Lower the vehicle.
  17. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  18. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  19. Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement .
  20. Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement : Manual Gearbox .
  21. Install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement : 2.0L Diesel LNP → 2.0L Diesel LLW .
  22. Install the transmission fluid cooler outlet pipe to the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement : 2.0L Diesel LNP → 2.0L Diesel LLW .
  23. Install the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
  24. Fill up the refrigerant. Refer to Refrigerant Recovery and Recharging .
  25. Fill up coolant fluid. Refer to Cooling System Draining and Filling .
  26. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  27. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
   


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