Cooling System

COOLANT CIRCUIT ASSEMBLY: EXPLODED VIEW
Note, one or more warnings are present in this procedure
Special tooling required
Clip pliers for hose clips (large size). Mot. 1202-01
Clip pliers for hose clips (small size) Mot. 1202-02
Remote operation pliers for hose clips. Mot. 1448
WARNING
To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair:
Vehicle: Precautions for the repair .
WARNING
When working in the engine compartment, take care as the radiator fan(s) may start up unexpectedly (risk of being cut).
To avoid any risk of serious burns when the engine is hot:

do not open the expansion bottle cap,
do not drain the cooling system,
do not open the bleed screw(s).
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CAUTION
When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the
water, fill and bleed the circuit and then measure the effective protection.
The criteria to be met are:

protection down to -25 C 2for cold and temperate countries,
protection down to -40 C 2for very cold countries.
CAUTION
Prepare for the flow of fluid, and protect the surrounding components.
-1-
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Illustration key: Description .
For fastenings with no specified tightening torque values, refer to the Table of Standard TorquesTightening torques: General information .
-2-
Marks Designations Informations
1 Cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting)
2 Clip
3 Engine cooling fan assembly (see Cylinder block assembly: Exploded view)
4 Expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting)
Clip pliers for hose clips (large size).(Mot. 1202-01)
5 Cooling radiator degassing pipe Clip pliers for hose clips (small size)(Mot. 1202-02)
Remote operation pliers for hose clips.(Mot. 1448 )
6 Cooling radiator inlet pipe Clip pliers for hose clips (small size)(Mot. 1202-02)
7 Cooling radiator degassing pipe Clip pliers for hose clips (small size)(Mot. 1202-02)
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(see 19A, Cooling, Electric coolant pump: Removal - Refitting)

8 Electric coolant pump pipe inlet
Clip pliers for hose clips (small size)(Mot. 1202-02)
9 Cooling radiator outlet pipe Clip pliers for hose clips (small size)(Mot. 1202-02)
10 Electric coolant pump (see 19A, Cooling, Electric coolant pump: Removal - Refitting)
Repair-10x06x01-02x50-1-10-1.xml
XSL version : 3.02 du 22/07/11
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COOLING RADIATOR: REMOVAL - REFITTING
WARNING
To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation
recommendations before carrying out any repair:
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WARNING
When working in the engine compartment, take care as the radiator fan(s) may start
up unexpectedly (risk of being cut).

CAUTION
When carrying out a repair that requires a complete change, it is essential to flush the
circuit with clean water, blast compressed air through the circuit to drive out the
water, fill and bleed the circuit and then measure the effective protection.
The criteria to be met are:

protection down to -25 C ± 2for cold and temperate countries,
protection down to -40 C ± 2for "extreme cold" countries.
-1-
CAUTION
Prepare for the flow of fluid, and protect the surrounding components.
Location and specifications (tightening torques, parts always to be replaced, etc.)(see 19A, Cooling,
Coolant circuit assembly: Exploded view) .
REMOVAL
1. REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post liftVehicle: Towing and lifting .
WARNING
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DANGER: HIGH VOLTAGE VEHICLE.
Risks of serious burns or electric shocks that may prove fatal.
Before carrying out any work on the vehicle, it is essential that you follow the
instructions regarding vehicle lockout. This work must be carried out by an employee
who is qualified and authorised to work on a high-voltage onboard networkVehicle:
Precautions for the repair .
Lockout the vehicleVehicle: Lockout - Removal of lockout .
Remove:
the engine undertray,
the front wheelsFront hub carrier assembly: Exploded view ,
the front section of the front wheel arch linersExterior body front trim assembly: Exploded view ,
the front bumperFront bumper assembly: Exploded view ,
the headlights(see Front signals - lighting assembly: Exploded view) ,
the engine cooling fan assembly(see 19A, Cooling, Coolant circuit assembly: Exploded view) .
Drain the cooling system(see 19A, Cooling, Cooling system: Draining - Refilling) .
-2-
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Unclip the air conditioning condenser from the cooling radiator.
Move the air conditioning condenser.
-3-
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Unclip the wiring from the upper air deflector(1 ) .
Remove:
the lower air deflector,
the upper air deflector.
Unclip air conditioning solenoid valve connector from the cooling radiator.
2. REMOVAL OPERATION
Separate the clips using the toolRemote operation pliers for hose clips.(Mot. 1448 ) from (see 19A, Cooling, Coolant circuit
assembly: Exploded view) :
the hose between cooling radiator and electric traction reduction gearing,
the degassing hose,
the hose between cooling radiator and expansion bottle,
the hose between cooling radiator and electric coolant pump.
Disconnect (see 19A, Cooling, Coolant circuit assembly: Exploded view) :

the hose between cooling radiator and electric traction reduction gearing,
the degassing hose,
the hose between cooling radiator and expansion bottle,
the hose between cooling radiator and electric coolant pump.
-4-
Unclip the hose between cooling radiator and electric traction reduction gearing.
Remove the cooling radiator(see 19A, Cooling, Coolant circuit assembly: Exploded view) .
REFITTING
1. REFITTING OPERATION
Proceed in the reverse order to removal.
Remove the lockout of the vehicleVehicle: Lockout - Removal of lockout .
Fill and bleed the cooling system(see 19A, Cooling, Cooling system: Draining - Refilling) .
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Repair-10x06x01x05-01x37-1-127-1.xml
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COOLINGRADIATOR:REPAIR
Equipment required
safety strap(s)
WARNING
Before carrying out any operation on a vehicle fitted with the Stop & Start system,
always follow the safety instructionsVehicle: Precautions for the repair .
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Before starting any operation check that the radiator is undamaged (not drilled, distorded or shocked);
there may be a risk of further leaking.
Note:
This repair method is applicable to the cooling radiator and also to the intercooler.
Before starting any operation check that the radiator is undamaged (not drilled, distorded or shocked);
there may be a risk of further leaking.
Note:
This repair method is applicable to the cooling radiator and also to the intercooler.
Equipment required to carry out the repairs:

Plastic repair kitVehicle: Parts and consumables for the repair ,
Radiator pin repair kitVehicle: Parts and consumables for the repair .
-1-
REPAIR
1. REPAIR PREPARATION OPERATION
WARNING
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Remove:
the engine undertray,
the front wheelsFront hub carrier assembly: Exploded view ,
the front section of the front wheel arch linersExterior body front trim assembly: Exploded view ,
the front bumperFront bumper assembly: Exploded view .
Strap the cooling radiator to the front end panel using the safety strap(s).
Remove the radiator mounting cross memberFront axle assembly: Exploded view .
2. REPAIR OPERATION
1- PREPARING THE SURFACES FOR BONDING
-2-
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Remove the damaged mounting pin from the cooling radiator
Cut the remaining section of the cooling radiator mounting pin(1 ) on the cooling radiator.
File down the base of the cooling radiator mounting pin to obtain a flat surface.
Sand the areas to be bonded using 80 gritsandpaper (dry).
Using plastic repair kit, clean the surfaces of the replacement mounting pin from the pin repair kit and
clean the radiator base.
-3-
2- BONDING
Apply the adhesive primer contained in the plastic repair kit.
Leave to dry (see product technical sheet).
Extrude:
20 mm of bead in order to obtain a homogenous mixture of the product before application,
the adhesive mixture on the base of the radiator and on the base of the replacement mounting pin (pin repair kit).
Position the replacement mounting pin on the base of the radiator and leave to dry (see product
technical sheet .
3. FINAL OPERATION
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Repair-10x06x01x05-01x22-1-3-1.xml
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COOLING SYSTEM: DRAINING - REFILLING
Instrument for testing the cooling circuit and the expansion bottle valve. Contains caps 554-01, 554-04, 554-06 Ms. 554-07
Fault finding and filling - bleeding the cooling circuit. Mot. 1700
Equipment required
compressed air nozzle
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coolant recovery tray
WARNING
To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation
recommendations before carrying out any repair:
WARNING
When working in the engine compartment, take care as the radiator fan(s) may start
up unexpectedly (risk of being cut).

-1-
CAUTION
The coolant helps to keep the engine running properly (heat exchange).
The system does not operate using pure water.
CAUTION
If the coolant is leaking from the expansion bottle cap, replace the valve.
CAUTION
Before the operation, protect the electrical accessories to prevent any risk of short
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circuiting and protect the belts to avoid damaging them.
DRAINING
WARNING
-2-
5AQ(5AQ)
Remove the front bumperFront bumper assembly: Exploded view .
Remove :
the expansion bottle cap,
the engine undertray.
Position the coolant recovery trayunder the vehicle.
5AQ(5AQ)
Move aside using the toolRemote operation pliers for hose clips.(Mot. 1448 ) the clip of the cooling
radiator outlet pipe on the electric coolant pump side.(see 19A, Cooling, Coolant circuit assembly: Exploded
view ) .
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Disconnect the cooling radiator outlet pipe from the electric coolant pump(see 19A, Cooling, Coolant
circuit assembly: Exploded view) .
Use a compressed air nozzleto blow air into the system through the cooling radiator outlet pipe opening
to remove as much coolant as possible.
CLEANING
Fill the cooling system with water through the expansion bottle.
Let the water run until the water collected from the cooling radiator bottom hose becomes clear.
Use a compressed air nozzle to blow air into the system through the expansion bottle opening to
remove as much as coolant as possible.
5AQ(5AQ)
Connect the cooling radiator outlet pipe from the electric coolant pump(see 19A, Cooling, Coolant
circuit assembly: Exploded view) .
Refit using the toolRemote operation pliers for hose clips.(Mot. 1448 ) the clip of the cooling radiator
outlet pipe on the electric coolant pump side(see 19A, Cooling, Coolant circuit assembly: Exploded view) .
-3-
FILLING
Note:
There are two procedures for filling the cooling system:

the procedure using the toolFault finding and filling - bleeding the cooling circuit.(Mot.
1700 ) recommended by Renault. It saves a considerable amount of time because it does not
require the cooling system bleed screws to be opened,
the procedure without a special tool.
1.
1- FILLING PROCEDURE USING THE TOOL (MOT. 1700)
Fill the cooling system with engine coolant recommended by the manufacturerVehicle: Parts and
consumables for the repair using the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) (see
Cooling system: Filling) (Technical Note 3857A, 19A, Cooling).
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2- FILLING METHOD WITHOUT SPECIAL TOOLS
CAUTION
It is essential to open all of the bleed screws to remove as much as air as possible in
the cooling system. Failure to perform this procedure may prevent the cooling system
from filling properly and may damage the engine.
-4-
Open the bleed screws(1 ) .
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Fill the cooling system with engine coolant recommended by the manufacturerVehicle: Parts and
consumables for the repair via the expansion bottle until it overflows.
Close the bleed screws as soon as the coolant starts to flow in a continuous stream.
Pressurise the system using the toolInstrument for testing the cooling circuit and the expansion
bottle valve. Contains caps 554-01, 554-04, 554-06(Ms. 554-07) to check that there are no leaks(see
19A, Cooling, Engine cooling system: Check) .
-5-
Refit the expansion bottle cap.
Clean any surfaces soiled by the coolant.
BLEEDING
CAUTION
Do not open the bleed screw whilst the engine is running; this would damage the
engine.
Remove the lockout of the vehicleVehicle: Lockout - Removal of lockout .
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Deactivate the air conditioning system so that the engine cooling fan is not operating from the start of
the operation.
Start the engine.
Run the engine at full power and at idling speed, until the engine cooling fan has started to operate two
times (time required for automatic degassing).
Check that the heating is operating correctly.
Allow the engine to cool until the coolant temperature is less than 50 C.
Make sure the coolant fluid level is at the "Maximum" mark.
Remove the coolant recovery tray.
Repair-10x06x01-01x73-1-84-1.xml
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COOLING SYSTEM FILLING AND DIAGNOSTIC TOOL: USE
Fault finding and filling - bleeding the cooling circuit. Mot. 1700
WARNING
Before carrying out any operation on a vehicle fitted with the Stop & Start system, always follow the safety
instructions Vehicle: Precautions for the repair
DESCRIPTION OF THE TOOL MOT. 1700
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-1-
-2-
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(1 ) Connection control between the vehicle's cooling system and tool Mot. 1700
(2 ) Pressure gauge
(3 ) Electric pump air inlet and outlet selection control
(4 ) Vacuum or pressure creation selection control
(5 ) Electric supply
(6 ) Socket for expansion bottle cap
(7 ) Electric pump protection fuse
(8 ) Electric pump stop/start switch
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(9 ) Connecting pipe between the vehicle's cooling system and tool Mot. 1700
-3-
-4-
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(10 ) Decanting bottle
(11 ) Indicator for reading the coolant level in the reservoir
(12 ) Reservoir filling opening
1. FAULT FINDING PROCEDURE FOR THE ENGINE COOLING SYSTEM
CAUTION
Failure to observe the following procedure can lead to the destruction of the engine.
1- FAULT FINDING PROCEDURE FOR THE EXPANSION BOTTLE CAP
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Position:
Control(1) to "0" ,
Control(2) to "3" ,
Control(3) to "7" ,
The on/off switch(4) to "OFF" .
-5-
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Screw on:
The expansion bottle cap at(5) on the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) ,
The adapter plug(6) (without the pipe) to the vehicle expansion bottle.
Connect the wires to the battery, observing the correct polarity.
-6-
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Position:
Control(1) to "1" ,
Control(3) to "6" ,
The on/off switch(4) to "ON" .
Note:
The pressure gauge needle should point to a pressure value and should settle at the expansion bottle valve
cap valve rating. If the needle does not indicate the rating or exceeds 2 bar, replace the expansion bottle
cap because the rating is incorrect.
Set the on/off switch(4 ) to "OFF" .
Note:
The needle of the pressure gauge must remain at the expansion bottle cap valve rating. If the needle drops
back down, replace the expansion bottle cap as it is leaking.
-7-
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Dump the pressure by turning the control(1 ) in the direction shown by the arrow.
2- FAULT FINDING PROCEDURE FOR THE ENGINE COOLING SYSTEM
-8-
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Connect the pipe of the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) to the adapter plug.
-9-
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Position:
Control(1) to "1" ,
Control(3) to "6" ,
Note:
The pressure gauge needle should point to a pressure value and should settle at the expansion bottle
valve cap valve rating.
- 10 -
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Set the control(3 ) to "7" .
Note:
The pressure gauge needle should not move. If it does not, find and repair any leaks on the cooling
system.
After repair, repressurise the cooling circuit (by restarting the previous operations).
- 11 -
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Gradually dump the pressure by turning the control(1 ) in the direction shown by the arrow.
- 12 -
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Disconnect the tool Fault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) from the vehicle.
2. FILLING THE COOLING CIRCUIT
- 13 -
This filling operation can be carried out after the cooling circuit has been totally or partially drained, and does not need the
bleed screws to be open. The cooling circuit is filled by vacuum.
CAUTION
Failure to observe the following procedure can lead to the destruction of the engine
1- CREATING A VACUUM IN THE ENGINE COOLING SYSTEM
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Position:
Control(1) to "0" ,
Control(2) to "3" ,
Control(3) to "7" ,
The on/off switch(4) to "OFF" .
- 14 -
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Check that:
The decanting bottle(5) is empty,
There is enough coolant in the reservoir of the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) .
- 15 -
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Fit the adapter plug to the vehicle's expansion bottle.
Connect the pipe of the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) to the adapter plug.
Connect the wires to the battery, observing the correct polarity.

- 16 -
Note:
During the operation, do not fit the expansion bottle cap on tool Mot. 1700
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Position:
Control(1) to "2" ,
Control(2) to "4" ,
Control(3) to "6" ,
Note:
The pressure gauge needle should show a vacuum.
- 17 -
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The cooling system hoses flatten.
Note:
If replacing a part which not does require the cooling system to be completely drained, it is essential to
position the switch (4) to "OFF" and the control (3) to "7" when the coolant starts to rise in the connecting
pipe between the expansion bottle and Mot. 1700.
- 18 -
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When the pressure gauge needle shows a vacuum of between 0.85and 0.95bar (depending on the vehicle), position:
The on/off switch(4) to "OFF" ,
Control(3) to "7" .
Note:
system.
After repair, create a vacuum in the cooling circuit (by restarting the previous operations).
2- FILLING THE COOLING CIRCUIT
- 19 -
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The hoses return to their original form.
- 20 -
The pressure gauge needle returns to zero.
Note:
For cooling systems with a coolant capacity greater than 10 litres, stop filling the cooling system before
the reservoir is empty.
To carry out this operation:
Position the control (3) to "7" ,
Readjust the coolant level in the reservoir.
Set the control (3) to "5" to fill the cooling system again.
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- 21 -
The cooling system is full once bubbles appear in the connecting pipe(7 ) between the expansion bottle and toolFault
finding and filling - bleeding the cooling circuit.(Mot. 1700 ) .
Disconnect the pipe (7 ) from the adapter plug.
Remove the adapter plug(6 ) .
Connect the adapter plug to the pipe to empty the remaining liquid in the pipe into the reservoir of the toolFault finding
and filling - bleeding the cooling circuit.(Mot. 1700 ) .
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3- PRESSURIZING THE COOLING SYSTEM
Refit the adapter plug and the pipe to the vehicle's expansion bottle in order to pressurise the cooling circuit to check
the cooling circuit sealing.
Refit the expansion bottle cap(8 ) on the toolFault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) .
- 22 -
Position:
Control(1) to "1" ,
Control(2) to "3" ,
Control(3) to "6" ,
Note:
The pressure gauge needle should point to a pressure value and should settle at the expansion bottle
valve cap valve rating.
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- 23 -
Note:
system.
After repair, repressurise the cooling circuit (by restarting the previous operations).
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Gradually dump the pressure by turning the control(1 ) in the direction shown by the arrow.
Disconnect the tool Fault finding and filling - bleeding the cooling circuit.(Mot. 1700 ) from the vehicle.
Fill the expansion bottle to overflow (only after a total draining of the cooling system).
- 24 -
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Bleed the engine cooling systemCooling system: Draining - Refilling .
- 25 -
Repair-10x06x09-01x79-1-1-1.xml
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- 26 -

Cooling System

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Cooling System

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COOLANT CIRCUIT ASSEMBLY: EXPLODED VIEW

Note, one or more warnings are present in this procedure

Special tooling required

Clip pliers for hose clips (large size). Mot. 1202-01

Clip pliers for hose clips (small size) Mot. 1202-02

Remote operation pliers for hose clips. Mot. 1448

To avoid any risk of serious burns when the engine is hot:

The criteria to be met are:

1 Cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting)

4 Expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting)

Clip pliers for hose clips (large size).(Mot. 1202-01)

Remote operation pliers for hose clips.(Mot. 1448 )

Clip pliers for hose clips (large size).(Mot. 1202-01)

Remote operation pliers for hose clips.(Mot. 1448 )

Clip pliers for hose clips (large size).(Mot. 1202-01)

(see 19A, Cooling, Electric coolant pump: Removal - Refitting)

Clip pliers for hose clips (large size).(Mot. 1202-01)

Remote operation pliers for hose clips.(Mot. 1448 )

Clip pliers for hose clips (large size).(Mot. 1202-01)

Remote operation pliers for hose clips.(Mot. 1448 )

XSL version : 3.02 du 22/07/11

Note, one or more warnings are present in this procedure

Special tooling required

Remote operation pliers for hose clips. Mot. 1448

To avoid any risk of serious burns when the engine is hot:

The criteria to be met are:

1. REMOVAL PREPARATION OPERATION

Position the vehicle on a two-post liftVehicle: Towing and lifting .

Risks of serious burns or electric shocks that may prove fatal.

Lockout the vehicleVehicle: Lockout - Removal of lockout .

Move the air conditioning condenser.

Disconnect (see 19A, Cooling, Coolant circuit assembly: Exploded view) :

Proceed in the reverse order to removal.

Remove the lockout of the vehicleVehicle: Lockout - Removal of lockout .

Note, one or more warnings are present in this procedure

Equipment required to carry out the repairs:

1. REPAIR PREPARATION OPERATION

Position the vehicle on a two-post liftVehicle: Towing and lifting .

Lockout the vehicleVehicle: Lockout - Removal of lockout .

Risks of serious burns or electric shocks that may prove fatal.

1- PREPARING THE SURFACES FOR BONDING

Sand the areas to be bonded using 80 gritsandpaper (dry).

Apply the adhesive primer contained in the plastic repair kit.

Leave to dry (see product technical sheet).

Proceed in the reverse order to removal.

Note, one or more warnings are present in this procedure

Special tooling required

Remote operation pliers for hose clips. Mot. 1448

compressed air nozzle

To avoid any risk of serious burns when the engine is hot:

The system does not operate using pure water.

Position the vehicle on a two-post liftVehicle: Towing and lifting .

Risks of serious burns or electric shocks that may prove fatal.

Lockout the vehicleVehicle: Lockout - Removal of lockout .

Position the coolant recovery trayunder the vehicle.

There are two procedures for filling the cooling system:

1- FILLING PROCEDURE USING THE TOOL (MOT. 1700)

Clean any surfaces soiled by the coolant.

Remove the lockout of the vehicleVehicle: Lockout - Removal of lockout .

Start the engine.

Check that the heating is operating correctly.

Make sure the coolant fluid level is at the "Maximum" mark.

Refit the expansion bottle cap.