1.6L Diesel: Removal

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover. .
3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
4. Drain the cooling system. Refer to STANDARD PROCEDURE .
5. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .

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6. Working on both sides, remove the bolts (1a), nuts (1b) and the front bumper reinforcement (1c).

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7. Remove the upper radiator hose (1).

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8. Remove the left side Charge Air Cooler (CAC) hose (1).

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9. Disconnect the cooling fan wire harness connector (1).
10. Disconnect the cooling fan resistor wire harness connector (2).

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11. Unlock retaining clips (1) and remove the coolant hose from fan shroud.

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12. Open the retaining clips (1a), remove the bolts (1b) and the A/C lines from the condenser.

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13. Remove the lower radiator hose (1).
14. Loosen clamp (2) and remove the right side CAC hose.

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15. Lift the spring (1a) and disengage the clips (1b).

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16. Working on both sides, to compress the spring (1a) and remove the retaining block (1b).

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17. Working on both sides, disengage the upper tabs and remove the radiator assembly (1).

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18. Remove the bolts (1) and the air deflector.

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19. Detach the retaining clips and remove the air duct (1).

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20. Compress the clips and remove the condenser (1).

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21. Unlock tabs and remove the CAC (1).

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22. Remove the cooling fan bolts (1).
23. Unhook the clips and remove the cooling fan (2) from the radiator.

INSTALLATION 

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1. Install the cooling fan (2) onto the radiator and engage the retaining clips.
2. Install the cooling fan bolts (1) and securely tighten.

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3. Install the Charge Air Cooler (1) and engage the retainers.

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4. Install the condenser (1) to the radiator and engage the retaining clips.

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5. Install the air duct (1) and engage the retaining clips.

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6. Install the CAC air deflector and securely tighten the bolts (1).

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7. Install the radiator assembly (1) and engage the upper tabs on both sides.

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8. Install the radiator retaining block (1b) and engage the spring clips on both sides.

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9. Engage the clips (1b) and lock the spring clip (1a).

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10. Install the CAC hose and securely tighten the clamp (2).
11. Install the lower radiator hose (1) and engage the spring clip.

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12. Install the A/C lines to the condenser and securely tighten the bolts (1b) and close the retainer clips (1a).

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13. Install the coolant hose and close the retaining clips (1).

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14. Connect the cooling fan resistor wire harness connector (2).
15. Connect the cooling fan wire harness connector (1).

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16. Install the CAC hose (1) and engage the spring clip.

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17. Install the upper radiator hose (1) and engage the spring clip.

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18. Install the front bumper crossbar (1a) and working from both sides, tighten the bolts (1c) and the nuts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
19. Install the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
20. Fill the cooling system. Refer to STANDARD PROCEDURE .
21. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
22. Install the engine cover.
23. Connect the negative battery cable.