Coolant Replacement

PROCEDURE

Radiator and cooling fan for 1.1 and 1.3 L engines1 – fan wiring harness bracket; 2 – fan shroud; 3 – clamp; 4 – expansion tank drain hose; 5 – fan thermoswitch; 6 – expansion tank; 7 – vent hose; 8 – expansion tank cap; 9 – rubber bushing; 10 – left radiator cover; 11 – radiator mounting bolt; 12 – radiator inlet hose; 13 – radiator; 14 – removable radiator mounting bracket; 15 – right radiator cover; 16 – electric cooling fan; 17 – radiator outlet hose

Radiator and cooling fan for 1.6 and 1.8 L engines1 – fan wiring harness bracket; 2 – fan shroud; 3 – electric cooling fan; 4 – clamp; 5 – expansion tank drain hose; 6 – expansion tank; 7 – expansion tank cap; 8 – vent hose; 9 – fan thermoswitch; 10 – O-ring; 11 – rubber bushing; 12 – left radiator cover; 13 – radiator mounting bolt; 14 – radiator; 15 – removable radiator mounting bracket; 16 – radiator inlet hose; 17 – right radiator cover; 18 – radiator outlet hose

Cooling system components for 1.6 and 1.8 L engines1 – heater drain pipe; 2 – connecting hose; 3 – radiator outlet hose; 4 – clamp; 5 – thermostat housing cover; 6 – cover bolt; 7 – O-ring; 8 – thermostat; 9 – water pump cover; 10 – pulley mounting flange; 11 – pulley; 12 – gasket; 13 – water pump housing; 14 – radiator inlet hose; 15 – hose; 16 – intake manifold heater thermoswitch; 17 – O-ring; 18 – coolant jacket connection; 19 – connection O-ring; 20 – gasket; 21 – heater coolant take-off connection; 22 – coolant temperature sensor; 23 – sensor O-ring; 24 – heater coolant supply hose; 25 – heater drain hose; 26 – expansion tank drain hose connection; 27 – automatic choke flap thermoswitch

Warning: Drain the coolant and open the expansion tank cap only when the engine is cold to avoid scalding.

PROCEDURE 1. Open the heater valve by setting the heater control lever on the instrument panel to the “Heat” position. 2. On 1.1 and 1.3 L engines, disconnect outlet hose 17 (see illustration

Radiator and cooling fan for 1.1 and 1.3 L engines) from radiator connection 13. Remove expansion tank cap 8 from expansion tank 6. 3. On 1.6 and 1.8 L engines and diesel engines, disconnect hose 18 (see illustration Radiator and cooling fan for 1.6 and 1.8 L engines) from thermostat housing cover 5 (see illustration Cooling system components for 1.6 and 1.8 L engines) and hose 2 from the water pump. Remove cap 7 (see illustration Radiator and cooling fan for 1.6 and 1.8 L engines) from expansion tank 6. 4. After all the coolant has drained, reconnect the hoses. 5. Fill the expansion tank with fresh coolant up to the “MAX” mark. Install the expansion tank cap. 6. Start the engine. If the coolant level has dropped, top up the coolant. 7. Warm up the engine until the electric cooling fan switches on. Stop the engine. 8. Check the coolant level after the engine has cooled down.