Special Tools

AU-525 Quick Connect Release Tool

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.

Warning: Refer to Radiator Cap Removal Warning in the Preface section.

2. Ensure engine is below 50°C before removing the coolant pressure cap.
3. Drain the cooling system. Refer to Cooling System Draining and Filling.
4. Remove the engine cover. Refer to Engine Cover Replacement for the 3.6L engine or Engine Cover Replacement for the 6.0L engine.
5. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
6. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement for the 3.6L engine or Air Cleaner Inlet Duct Replacement for the 6.0L engine.
7. Remove the mass air flow meter. Refer to Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for the 3.6L engine or Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for the 6.0L engine.
8. Detach the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.

Warning: Refer to Safety Glasses Warning in the Preface section.

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle.
10. Remove the air deflector. Refer to Front Air Deflector Replacement.
11. Detach the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
12. Lower the vehicle.
13. Detach the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement.
14. Remove the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.
15. Place a suitable container beneath the radiator and engine.




Note: When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.

16. Disconnect the transmission cooler line (2) from the flexible hose (1) using the AU-525 .

•	Detach plastic cover from hose fitting and slide along pipe.

•	Open the AU-525 then close and clip around the hose to be disconnected.

•	While holding the flexible hose (1) push the hose inwards with one hand, then pull back to separate from the steel hose piping (2).

•	Repeat procedure for the second fitting.




17. Remove the radiator support brackets (2) from top of radiator by rasing the securing lock (3) 10 mm and then sliding the bracket off the radiator slide pin (1). Carry out same procedure for other bracket.



18. Disconnect the cooling fans electrical connector (2) from the main wiring loom connector (1).



19. Remove the two radiator and condenser retaining bolts (1).




Note: When manoeuvring the condenser take care not to fracture the A/C lines.

20. Detach the condenser by lifting it out of the retaining brackets located on the radiator assembly.



21. Remove the radiator and fan assembly, by tilting it forward and lifting it out of the rubber grommets located in the cross member.

1. Install the radiator into the rubber retaining grommets located in the cross member.



2. Install the condenser into the radiator

Caution: Refer to Fastener Caution in the Preface section.

3. Install the 2 radiator and condenser retaining bolts (1) and tighten to 11 N·m (97 lb in).



4. Install the radiator retaining brackets (2), onto the radiator slide pin (1).
5. Secure the retaining brackets by pushing the securing lock (3) downwards until lock reaches bottom of radiator bracket.



6. Connect the cooling fans electrical connector (2) to the main wiring loom connector (1).




Note: Make sure the cloth protecting the hose openings from contamination is removed from the hose openings before carrying out the installation procedure.

7. Connect the flexible hoses (1) to the transmission cooler lines (2). Listen for an audible click to confirm fitting.
8. Push plastic cover forward along pipe and clip onto hose fitting.

Warning: Refer to Safety Glasses Warning in the Preface section.

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

9. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle.
10. Install the outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement.
11. Lower vehicle.
12. Install the coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.
13. Install the coolant recovery reservoir hose. Refer to Coolant Recovery Reservoir Replacement.
14. Install the inlet hose. Refer to Radiator Inlet Hose Replacement.
15. Install the air deflector. Refer to Front Air Deflector Replacement.
16. Install the mass air flow meter. Refer to Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for the 3.6L engine or Mass Airflow Sensor/Intake Air Temperature Sensor Replacement for the 6.0L engine.
17. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement for the 3.6L engine or Air Cleaner Inlet Duct Replacement for the 6.0L engine.
18. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
19. Install the engine cover. Refer to Engine Cover Replacement for the 3.6L engine or Engine Cover Replacement for the 6.0L engine.
20. Install the battery ground lead to the vehicle. Refer to Battery Negative Cable Disconnection and Connection.
21. Fill the cooling system. Refer to Cooling System Draining and Filling.
22. Inspect cooling system for leaks.