TSB: 01-018/03

1999 - 2001 Protege - COOLANT LEAKAGE FROM LOWER RADIATOR TANK

APPLICABLE MODEL(S)/VINS

1999 - 2001 Protege

DESCRIPTION

Some customers may experience a coolant leak from the lower radiator tank seal. The leak may occur around the radiator fan mounting brackets due to insufficient compression of the seal. Customers experiencing this concern should have their vehicles repaired using the REPAIR PROCEDURE below.

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the radiator from the vehicle following the Workshop manual section 01-12: RADIATOR REMOVAL/INSTALLATION

CAUTION: Lay the radiator on cardboard while working to prevent damage and cap the cooler fittings on the radiator with plugs to prevent leakage and to prevent water / dirt from entering the radiator.

3. Clean the lower radiator tank thoroughly.

4. Turn the radiator so the lower tank is at the top.

5. Re-crimp the tabs on the lower radiator tank with the special tools in numerical order following the instructions below:

• Re-crimp tabs 1, 2, 3, 4, 5, 6 using Radiator Crimping Pliers SST AKS-UN-164:

1. Set the bottom of the tool on the radiator tank.

   

2. Set the tool vertical to the core, use your thumb under the tool to secure it, and squeeze to crimp.

• Set the Initial Bend on tab 7 using Radiator Flat pliers SST AKS-UN-163 see step a and b below:

1. Bend only the center tab toward the tank approximately 30 degrees with the flat pliers (STAKS-UN-163)

   CAUTION: Do not bend the tab more than 30 degrees with the flat pliers or it may break.
   
   

   Before crimping

   Initial bend 30 degrees from vertical using Radiator Flat Pliers SST AKS-UN-163

   
   

2. Now crimp tab 7 using the Radiator Crimping Pliers SST AKS-UN-164.

6. Re-crimp the tabs on the lower radiator tank with the special tool in numerical order 8 through 14 observing the notes below:

• Re-crimp tabs 8, 9, 10, 11, 12, 13 using Radiator Crimping Pliers SST AKS-UN-164:

1. Set the bottom of the plate in the tool.

   

2. Set the tool vertical to the core, use your thumb under the tool to secure it, and squeeze to crimp.

• Set the Initial Bend on tab 14 using SST Radiator Flat Pliers SST AKS-UN-163 see step a and b below:

1. Bend only the center tab toward the tank approximately 30 degrees with the flat pliers (STAKS-UN-163)

   CAUTION: Do not bend the tab more than 30 degrees with the flat pliers or it may break.
   
   

   Before crimping

   Initial bend 30 degrees from vertical using Radiator Flat Plier SST AKS-UN-163

   
   

2. Now crimp tab 14 using the Radiator Crimping Pliers SST AKS-UN-164.

7. Install the radiator to the vehicle following the Workshop manual section 01-12: RADIATOR REMOVAL/INSTALLATION

8. Refill the engine cooling system following the Workshop Manual 01-12 ENGINE COOLANT REPLACEMENT

9. Verify repair.

SST INFORMATION

WARRANTY INFORMATION

Note: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.