Peugeot 405 Manual

Radiator - removal, inspection and refitting
Cooling, heating and ventilation systems / Radiator - removal, inspection and refitting


Removal
1 Disconnect the battery negative lead.

2 Where applicable, disconnect the wiring from the coolant level sensor, mounted in the right-hand side of the radiator.

3 Similarly, where applicable disconnect the wiring from the cooling fan switch, mounted left-hand side of the radiator.

4 Drain the cooling system as described in Chapter 1.

5 Where applicable, depress the securing clip, and release the air inlet tube from the body front panel, above the radiator (see illustrations).

3.5a Depress the securing clip . . .
3.5a Depress the securing clip . . .

3.5b . . . and withdraw the air intake tube
3.5b . . . and withdraw the air intake tube

6 Where applicable, disconnect the wiring plug and the vacuum hose from the MAP sensor, located above the radiator, then unscrew the two bolts securing the sensor mounting bracket to the body front panel, and remove the sensor.

7 Disconnect the upper radiator hose from the left-hand end of the radiator, with reference to Section 2.

8 It is now necessary to disconnect the lower radiator hose(s) from the right-hand side of the radiator. On some models, particularly those where conventional hose clips are used, this is a straightforward task. On other models (where bayonet connectors are used on a large-capacity radiator), it is impossible to gain access to the lower radiator hose connections without removing the body front panel assembly, as described in Chapter 11 (see illustration).

3.8 Lower radiator hose connections viewed with body front panel removed
3.8 Lower radiator hose connections viewed with body front panel removed

9 Once all the radiator hoses have been disconnected, proceed as follows.

10 If not already done, working at the top of the radiator, release the two securing clips, and tilt the radiator back towards the engine (see illustration).

3.10 Releasing a radiator upper securing clip
3.10 Releasing a radiator upper securing clip

11 Lift the radiator from the engine compartment (see illustration).

3.11 Lifting out the radiator
3.11 Lifting out the radiator

Inspection
12 If the radiator has been removed due to suspected blockage, reverse-flush it as described in Chapter 1. Clean dirt and debris from the radiator fins, using an air line (in which case, wear eye protection) or a soft brush. Be careful, as the fins are sharp, and easily damaged.

13 If necessary, a radiator specialist can perform a Уflow testФ on the radiator, to establish whether an internal blockage exists.

14 A leaking radiator must be referred to a specialist for permanent repair. Do not attempt to weld or solder a leaking radiator, as damage to the plastic components may result.

15 In an emergency, minor leaks from the radiator can be cured by using a suitable radiator sealant, in accordance with its manufacturerТs instructions, with the radiator in situ.

16 If the radiator is to be sent for repair or renewed, remove all hoses, and the cooling fan switch (where fitted).

17 Inspect the condition of the radiator mounting rubbers, and renew them if necessary.

Refitting
18 Refitting is a reversal of removal, bearing in mind the following points: a) Ensure that the lower lugs on the radiator are correctly engaged with the mounting rubbers in the body panel.

b) Reconnect the hoses with reference to Section 2, using new O-rings where applicable.

c) Where applicable, refit the body front panel assembly, referring to Chapter 11.

d) On completion, refill the cooling system as described in Chapter 1.


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