Note. When loosening the radiator cap on a hot engine, certain precautions must be taken to avoid scalding. It is correct to turn off the engine and let it cool down. Wrap the radiator cap with a rag, turn it counterclockwise first to the first stop and relieve pressure in the system. Then finally remove the cap from the radiator.
Checking the coolant level
1. On a cold engine, check the coolant level in the expansion tank of the cooling system. The level should be between the MIN and MAX marks on the tank wall.
2. If the fluid level is at or below the MIN·mark, add fluid to bring the level up to the MAX mark. Remove the radiator cap and make sure the radiator is filled with coolant. Add if necessary.
3. Start the engine and check for coolant leaks. If necessary, perform a pressure test of the radiator to determine its suitability for further use and to identify micro sources of leaks.
Emptying and refilling
1. Remove the radiator cap.
2. In the passenger compartment, move the heater control levers to the HOT position (Hot).
3. Install a receiving container under the radiator drain plug. Remove the drain plug.
4. Turn out a drain plug of the block of cylinders located under a final collector in a back part of the engine. On 3.0L models, loosen the air release plug located near the water outlet on the intake manifold.
5. After the water has drained out, replace the radiator drain plug. Don't tighten it too tight.
6. Lubricate the drain plug of the cylinder block with sealant and screw it into place, firmly tightening it.
7. Fill the system with fresh coolant, which is the correct mixture of water and antifreeze (with anti-corrosion additives) (see tables of sizes and adjustments at the end of the guide).
8. On 3.0L models, tighten the air release plug.
9. With the radiator cap removed, start the engine and carefully add coolant as air pockets come out.
10. Screw on the radiator cap and wait for the engine to warm up to normal operating temperature, accompanied by the opening of the thermostat. Check engine for water leaks.
11. Stop the engine and after it has cooled down, check the coolant level again.
12. Add liquid to the expansion tank, bringing its level to the MAX mark. Check the correct installation and tightening of the radiator and expansion tank caps.
Late Years 4.2L Models Equipped with Fuel Injection (EFI)
The procedure is practically the same as described above for models of early production years.
The only exception is the presence of an air release plug on the engine (as on 3.0 l models), which is located in front of the pressure chamber of the air path (see accompanying illustration). Therefore, on 4.2L EFI engines, all additional procedures related to 3.0L models must be completed.
Removing
1. Drain the coolant from the radiator.
1 - expansion tank; 2 - washers; 3 - overflow hose of the expansion tank; 4 - radiator cap; 5 - rubber pads; 6 - ventilation hose; 7 - radiator; 8 - top hose; 9 - drain plug; 10 - lower hose; 11 - top casing; 12 - lower casing
2. Disconnect the upper hose and the expansion tank overflow hose from the radiator (the radiator with related components is shown in the accompanying illustration).
3. On models equipped with a temperature-sensitive radiator switch, disconnect the electrical wiring from the sensor.
4. On 4.2 l models, disconnect the lower and ventilation hoses from the radiator.
5. On 3.0L models, disconnect the lower radiator hose from the transfer pipe.
6. On models with AT, disconnect the oil cooler hoses from the radiator. Cap the ends of the hoses to prevent dirt from entering the oil cooler and to minimize transmission fluid loss.
7. Give bolts of fastening of the top casing of a radiator.
8. Release the clamps securing the upper radiator casing to the lower one and remove the upper casing from the vehicle.
9. Remove the lower radiator shroud.
10. Give the bolts of fastening of a radiator located in the top part of the latter and remove a radiator from the car.
Note. When removing a used radiator from a vehicle, do not leave it empty for a long time. You should immerse the radiator in a bath of clean water, or simply pour water into it. Otherwise, the engine may overheat when it is put into operation, due to a violation of the circulation in the cooling system due to blockage of the internal channels of the radiator with dried deposits.
Washing and cleaning
1. Remove the radiator from the vehicle.
2. Connect a garden hose to the radiator inlet and backflush the radiator (see accompanying illustration). Continue flushing the radiator until clean water flows out of it.
Note. If an excessive rise in pressure in the hose or low water output indicates a severe obstruction of the internal channels of the radiator that cannot be repaired by backflow flushing, the radiator should be taken to a specialist workshop for refurbishment.
3. Install the radiator vertically (How is it installed on the car?) and rinse it from the outside on both sides with a high-pressure water jet. To avoid damage to the heat exchanger plates, try not to bring the hose nozzle to the radiator closer than 40 ÷ 50 cm. Continue flushing until all dirt deposits are removed from the gaps between the heat exchanger plates.
Installation
1. Installation is carried out in the reverse order.
2. Insert the radiator assembly into the vehicle's engine compartment, ensuring that the two rubberized guide pins are properly positioned on the cross member.
3. Place the radiator in working position and tighten the fixing bolts firmly.
4. On models with AT, remove the plugs from the oil cooler hoses and connect the latter to the fittings of the side radiator tanks. Tighten the hose clamps securely.
5. Where required, connect electrical wiring to the temperature sensitive switch.
6. Connect hoses to a radiator, having followed correctness of installation of fixing collars.
7. Fill the cooling system with coolant. Start the engine and check for water leaks.
8. On models with AT, check the transmission fluid level, also check the transmission for signs of leaks.