Cooling system

REPLACING THE COOLANT

REQUIRED TOOLS

• [1]. Check plug (ref. 169 589 00 91 00) (Fig.36).

DRAINING

The engine must be cold.

• Disconnect the battery.
• Remove the expansion tank cap.
• Raise and support the front of the vehicle.
• Remove the engine undertray.
• Place a container under the radiator and the cylinder block to collect the coolant.
• Open the radiator drain plug (1) and the cylinder block drain plug (2) (Fig.35).

Fig. 35

• Allow the coolant to drain completely.
• Close plugs (1) and (2).

FILLING AND BLEEDING

Never reuse used coolant when replacing the radiator, the cylinder head or the cylinder head gasket.

• Screw the check plug [1] onto the expansion tank (1) (Fig.36).

Fig. 36

• Connect the control unit (2) to the check plug [1].
• As illustrated, set up an assembly to create a vacuum to fill and bleed the cooling system.
• Connect a compressed air hose (3).
• Open the outlet valve (4) (a vacuum is created in the cooling system).
• Open the inlet valve (5) long enough for the inlet hose (6) to fill with coolant.
• Close the outlet valve (4) when the display of the control unit (2) is in the green range.
• Remove the compressed air hose (3) and check that the vacuum remains stable for 30 seconds.
• Open the inlet valve (5) (the cooling system fills).
• Open the outlet valve (4) when coolant is no longer being drawn in.
• Remove the assembly.
• Fill the expansion tank up to the base of the filler tube.

WATER PUMP

REQUIRED TOOLS

• [1]. Subframe retaining bolt (ref. 169 589 00 62 00) (Fig.37).

REMOVAL

• Remove the air filter housing.
• Lower the subframe:

• remove the air filter housing,
• the throttle actuator (vehicles with particulate filter) or the intake air throttle (vehicles without particulate filter),
• remove the steering column universal joint bolt, then separate the joint (lock the steering wheel),
• support the radiator,

Fig. 37

• remove the engine undertray.
• move the rear of the wheel arch liners aside,
• unhook the rubber exhaust mountings,
• remove the earth strap bolt from the oil sump,
• with manual gearbox, unclip the clutch hydraulic control pipe from the gearbox and the bulkhead,
• with xenon headlamps, disconnect the height sensor connector and remove its mountings,
• fit a support device under the subframe,
• remove the 4 subframe mounting bolts (1) (Fig.37),
• in place of the subframe mounting bolts, fit the retaining bolts with the stops [1],

Make sure the stops are centred on the retaining bolts.

• remove the 4 subframe mounting bolts (2),
• lower the subframe.

Before lowering the subframe, make sure no wiring harness, hose or pipe will obstruct its descent.

• Drain the cooling system (see relevant operation).
• Remove the auxiliary drive belt (see relevant operation).
• Remove the bolts (3) from the water pump pulley (4) (fig.38).

Fig. 38

• Remove the bolts (5), then remove the water pump (6).

INSTALLATION

Observe the following points:

• clean the mating surface on the cylinder block and on the water pump housing,
• replace the sealing gasket,
• refill the cooling system and bleed it.

THERMOSTAT HOUSING

REMOVAL

• Remove the air filter housing.
• Remove (Fig.39):

• vehicles without particulate filter, the intake air throttle,
• vehicles with particulate filter, the motorized throttle body.

Fig. 39

1. 1
   Vehicle without particulate filter
2. 2
   Vehicle with particulate filter.

• Drain the cooling system (see relevant operation).
• Disconnect the various hoses attached to the thermostat housing.
• Remove the screws (1) then the thermostat housing (2) (Fig.40).

Fig. 40

INSTALLATION

Observe the following points:

• replace the seal (3),
• refill the cooling system and bleed it.

ENGINE COOLING RADIATOR

REMOVAL

• Vehicles up to identification number J176282: drain the air conditioning circuit.
• Remove the engine undertray.
• Drain the cooling system (see relevant operation).
• Remove the front bumper (see the relevant operation in the 'BODYWORK' chapter).
• Remove (Fig.41):

• the air intake pipe (1),
• the air filter housing (2).

Fig. 41

• Remove (Fig.39):

• vehicles without particulate filter, the intake air throttle,
• vehicles with particulate filter, the electronic throttle body,
• the charge air hose (3) (Fig.41).

• Remove the charge air/air intercooler.
• Without disconnecting its lines, set the windscreen washer reservoir aside.
• Secure the radiator so that it does not fall.
• Vehicles with automatic gearbox: remove the screws (4) of the gearbox lines (Fig.42).

Fig. 42

• Disconnect or unclip the various connectors, cable ties or lines on the fan support.
• Remove the radiator hoses.
• Vehicles up to identification number J176282:

• remove the line (5),
• disconnect the air conditioning pressure switch connector (6) (Fig.43),
• remove the line (7),
• remove the dehydrator (8).

Fig. 43

• Remove the screws (9) then the lower crossmember (10) (Fig.44).

Fig. 44

• Except vehicles up to identification number J176282, unclip the condenser from the radiator and secure it so that it does not fall.
• Remove the radiator from below with the fan support.

INSTALLATION

Observe the following points:

• Vehicles up to identification number J176282: refill the air conditioning circuit,
• refill the cooling circuit and bleed it.

Cooling

1. 1
   Radiator
2. 2
   Radiator bleed screw
3. 3
   Air guide
4. 4
   Upper radiator hose
5. 5
   Lower radiator hose
6. 6
   Cooling fan motor
7. 7
   Cooling fan motor support
8. 8
   Expansion tank
9. 9
   Cap
10. 10
    Water pump
11. 11
    Screw (replace): 1.2 daN.m
12. 12
    Water pump pulley
13. 13
    Screw: 1.3 daN.m
14. 14
    Seal
15. 15
    Thermostat housing
16. 16
    Heater core.