9-3 1999

Removal & Installation

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2.0L Engine



  1. Before servicing the vehicle, refer to the precautions.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Remove the front grille.
  6.  
  7. Remove the light clusters and the headlamps.
  8.  
  9. Loosen and move aside the air deflectors by the condenser.
  10.  
  11. Open the expansion tank pressure cap and release any overpressure.
  12.  
  13. Disconnect the battery, remove the air venting hose and lift out the battery.
  14.  
  15. Loosen the battery tray, cut of the cable ties for the wiring and remove the battery tray.
  16.  
  17. Disconnect the hose from the throttle body and plug it. Remove the hose from between the charge air cooler and charge air pipe.
  18.  
  19. Remove the power steering fluid pipe from the brackets on the radiator cross member and below the battery tray.
  20.  
  21. Disconnect the vent hose from the radiator crossmember, cut of the cable ties and move aside the hose.
  22.  
  23. Unplug the radiator fan connector.
  24.  
  25. Remove the power steering fluid reservoir from the bracket and move aside the reservoir.
  26.  
  27. Raise the car, remove the lower cover and the air shields.
  28.  
  29. Place a receptacle under the radiator and drain the coolant.
  30.  
  31. Remove the condenser retaining bolts.

    Click image to see an enlarged view

    Fig. Removing the condenser retaining bolts (15), hose claps (16) and vent hose (17)

  32.  
  33. Lower the vehicle, disconnect the lower coolant hose from the radiator and disconnect the upper coolant hose from the radiator and the thermostat housing.
    NOTE
    There is still plenty of coolant in the engine, always have a suitable container under the engine when working on the cooling system.

  34.  
  35. Remove the vent hose from the radiator.
  36.  
  37. Remove the bolts securing the EGR valve and move the valve to one side
  38.  
  39. Unhook the condenser from the radiator.
  40.  
  41. Cut the cable tie from the lower coolant hose. Remove the radiator fan cowling from the radiator.

    Click image to see an enlarged view

    Fig. Removing the radiator fan cowling from the radiator

  42.  
  43. Remove the clamps that secure the radiator to the radiator crossmember and remove the fan cowling.
  44.  
  45. Remove the second hose from the charge air cooler.
  46.  
  47. Remove the A/C compressor cable from the radiator and remove the A/C pipe from the radiator crossmember.
  48.  
  49. Lift up the radiator.
  50.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Fill with coolant, check the integrity of the system and bleed it as follows:
    NOTE
    The air conditioning must be off.

    1. Connect exhaust hoses to both the engine exhaust system and the auxiliary heater exhaust system and start the engine.
    2.  
    3. Start the parking heater with the diagnostic tool.
    4.  
    5. Check that there is a continuous flow of coolant in the hose from the thermostat housing to the expansion tank. Rev up the engine briefly to ensure circulation of the fluid.
    6.  
    7. Run the engine until the thermostat has opened.
    8.  
    9. Shut off the engine and top up the cooling system if needed.
    10.  

  4.  

2.3L Engine



  1. Before servicing the vehicle, refer to the precautions.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Remove the front lower cover.
  6.  
  7. Drain the coolant from the radiator.
  8.  
  9. Lower the vehicle to the floor.
  10.  
  11. Undo the hose clip on the upper radiator hose.
  12.  
  13. Remove the fan assembly
  14.  
  15. For cars with automatic transmission, also remove the connections to the oil cooler on the transmission.
  16.  
  17. Loosen the cooling system vent hose.
  18.  
  19. Unplug the A/C compressor's connector.
  20.  
  21. Loosen the lower radiator hose from the coolant pump (attached with a hose clamp at the pump).
  22.  
  23. Detach the radiator from the body.
    NOTE
    If the radiator is to be removed for some time, it should be filled with liquid and the pipe connections plugged.



    Click image to see an enlarged view

    Fig. Radiator attaching mechanism

  24.  

To install:


NOTE
Make sure that the hose clip on the lower radiator hose is situated as high up as possible, close to the coolant pump connection, when installing the radiator.

  1. Installation is the reverse of removal.
  2.  
  3. Switch off the A/C or ACC. Fill with coolant to the MAX level. Do not forget to close the drain plug on the radiator first.
  4.  
  5. Start the engine and run unloaded at varying engine speeds until warm and the radiator fan starts.
  6.  
  7. Turn off the engine and top up to the MAX level.
  8.  
  9. Check the oil level in the automatic gearbox and top up as necessary.
  10.  
  11. Switch off the engine. Raise the vehicle.
  12.  
  13. Check for any leakage. Install the lower front cover.
  14.  

 
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