Removal
1. Tank cover; 2. Tank; 3. Clamp; 4. Tank hose; 5. Rubber cushion (top); 6. Mounting bracket (right); 7. Radiator cap; 8. Mounting bracket (left); 9. Radiator; 10. Rubber cushion (lower); 11. O-ring; 12. Drain plug; 13. Drain hose; 14. Clamp; 15. Radiator hose (lower); 16. Cooling fan assembly; 17. Radiator hose (upper); A. To the outlet pipe; B. To the inlet pipe.
Radiator
1. Remove the engine protection from the bottom.
2. Drain the engine coolant from the radiator. See above.
Attention. Perform this operation when the engine is cold.
3. Remove the air duct (inlet). See chapter «Mechanical part of the engine».
4. Disconnect the connectors from the fan motors and move the wiring to the side.
5. Disconnect the hose (upper) from the radiator and a hose from the tank.
6. Remove the mounting brackets (right and left) and rubber cushion (top) and tilt the radiator forward.
7. Remove the radiator cooling fan assembly (1). See below.
Attention. When removing, do not damage the radiator core.
8. Disconnect the radiator hose (lower).
Removal and installation
Removal
Attention:
- Do not remove the radiator cap when the engine is hot. High pressure coolant splashing out of the radiator can cause serious burns.
- Wrap the lid with a thick cloth. First, unscrew the cap a quarter turn and release the pressure. Then unscrew the cap all the way.
9. Remove the radiator.
Attention. Do not damage or scratch the radiator core.
Installation
Installation is carried out in the reverse order of removal.
Disassembly and assembly
Preparation
1. Place a gasket on the cutting edge of the radiator pliers (special tool).
Gasket dimensions (width x length x thickness): 18 x 8.5 x 1.5 mm.
2. Make sure that when closing the pliers (special tools KV99103510) size «N» is about 7.6 mm.
3.Adjust the size if necessary «N» gasket.
Disassembly
1. Remove the upper and lower tanks using radiator pliers (special tool).
Grasp the crimped edge and bend it upward until the radiator pliers come off (special tool KV991G3520).
Attention. Do not fold back excessively.
- In areas where radiator mites (special tool KV99103520) cannot be used, bend the edge with a screwdriver.
Attention. Don't damage the tank.
2. Remove the rubber seal.
3. Make sure the edges are folded vertically.
Assembly
1. Clean the contact area of the tank.
2. Install the new rubber seal by pressing it in with your fingers.
Attention. Do not twist the rubber seal.
3. Caulk the tank in the order indicated by the numbers in the figure using radiator pliers (special tool).
- In areas where radiator mites (special tool. KV99103510) cannot be used, use pliers.
4. Make sure the lip is fully crimped.
Height «N»: 8.0-8.4 mm.
5. Make sure there are no leaks. See above.
Check after assembly
1. Apply pressure using the adapter (suitable special tools) (A) and pump (suitable special tools,).
Test pressure. See paragraph below. «Technical data and specifications».
Attention. To prevent the hose from coming off when pressure is applied, securely secure it with a clamp.
2. Check for leaks by lowering the radiator into a container of water and applying test pressure.
Check after installation
- Check for coolant leaks by applying pressure using an adapter (suitable special tool) and pump (suitable special tools). See above.
- Start the engine and warm it up. Carry out a visual check and make sure there are no coolant leaks.