Repair Procedures

Removal and Installation

1. Disconnect the battery negative terminal (A).

Tightening torque:
4.0 - 6.0 N.m (0.4 - 0.6 kgf.m, 3.0 - 4.4 lb-ft)

2. Remove the radiator grille upper cover (B).




3. Remove the air cleaner assembly.
4. Remove the battery and battery tray.
5. Remove the under cover.
6. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.





WARNING:
Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

7. Remove the radiator upper hose (A), lower hose (B).




8. Disconnect the ATF cooler hose (A/T only).
9. Disconnect the fan motor connector (A).








10. Remove the radiator support upper member assembly (A) for convenience sake.

Tightening torque:
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 7.9 lb-ft)





NOTE:
The bottom side bolt (A) which can be seen after removing the under cover should be loosened for removal of the radiator support upper member assembly.




11. Disconnect the over flow hose from the radiator.
12. Disconnect the A/C pressure pipe (A) from the radiator assembly (B).




13. Separate the condenser (A) from the radiator assembly (B) by removing the bolts (C).

Tightening torque:
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 7.9 lb-ft)








14. Remove the radiator bracket.
15. Remove the radiator assembly.
16. Remove the radiator cooling fan (A).

Tightening torque:
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 7.9 lb-ft)




17. Installation is in the reverse order of removal.
18. Fill the radiator with coolant and check for leaks.

NOTE:
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn off engine and let it cool down. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put the radiator cap on tightly, then run engine again and check for leaks.

Inspection

Radiator Cap Testing
1. Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester.




2. Apply a pressure of 93.16 - 122.58kpa (0.95 - 1.25kg/cm2, 13.51 - 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Radiator Leakage Test
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 - 122.58kpa (0.95 - 1.25kg/cm2, 13.51 - 17.78psi).




3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

NOTE:
Check for engine oil in the coolant and/or coolant in the engine oil.