Repair Procedures

Inspection

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




2. Apply a pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2, 14 - 19psi).
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 a pressure tester on it.




2. Apply a pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2, 14 - 19psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. If the pressure drops, check hoses, the radiator and the water pump for leakage. If there is no leakage, inspect the heater core, the cylinder block and the cylinder head.
5. Remove the tester and reinstall the radiator cap.

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

Removal

WARNING:
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.

1. Disconnect the negative terminal from the battery.

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

2. Remove the engine cover (A).




3. Remove the engine side cover.
4. Loosen the drain plug and drain the engine coolant.
5. Remove the air duct (A), and the air cleaner assembly (B).

Tightening torque
Hose clamp bolt: 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)
Air cleaner assembly bolts: 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




6. Disconnect the radiator upper hose (A) and lower hose (B).




7. Remove the radiator & cooling fan assembly from the vehicle.
8. Disconnect the ATF cooler hoses (A).




9. Disconnect the fan motor connector (A).
10. Remove the radiator & condenser mounting bolt (B).




11. Remove the radiator & cooling fan assembly from the vehicle.

Installation

1. Installation is reverse order of removal.
2. Connect the fan motor connector.
3. Install the radiator upper hose & lower hose, and connect the ATF cooler hoses.
4. Fill the radiator with coolant and check for leaks.