Radiator: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Loosen a drain plug (2) to drain Engine Coolant (EC).
3. Disconnect oil cooler hose (1) on automatic transmission (A/T).





4. Disconnect radiator inlet hose and outlet hose from the engine.





5. Remove fan guide (1), clips (3) on both sides and the bottom lock, then remove lower fan guide (3) with fan shroud (4).
6. Disconnect the reserve tank hose (4) from radiator.





7. Remove bracket (5).
8. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade.
9. Remove rubber cushions on both sides at the bottom.

INSPECTION
Radiator Cap
Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the standard range.

Valve opening pressure: 88.3 - 117.7 kPa (12.8 - 17.1 psi)

Cap tester: J-24460-01
Adapter: J-33984-A
Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap.





Valve opening vacuum 1.96 - 4.91 kPa (0.28 - 0.71 psi)

Radiator Core
1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.

Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.

Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (28.5 psi) with a cap tester:
- Leakage from the radiator
- Leakage from the coolant pump
- Leakage from the water hoses
- Check the rubber hoses for swelling.





Cap tester: J-24460-01
Adapter: J-33984-A





INSTALLATION
1. Install rubber cushions on both sides of radiator bottom.
2. Install radiator assembly with hose, taking care not to damage the radiator core with a fan blade.
3. Install bracket (6) and support the radiator upper tank with the bracket (5) and secure the radiator.
4. Connect reserve tank hose (4).
5. Install lower fan guide (3).
6. Connect radiator inlet hose and outlet hose to the engine.
7. Connect oil cooler hose (1 ) to automatic transmission.
8. Connect battery ground cable.





9. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank.
Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.
- Remove radiator cap.
- Fill with engine coolant (EC) to the radiator filler neck.
- Fill with EC to the "MAX" line on the reservoir.
- Start the engine with the radiator cap removed and bring to operating temperature by running engine at 2,500 - 3,000 rpm for 30 minutes.
- By EC temperature gauge reading make sure that the thermostat is open.
- If air bubbles come up to the radiator filler neck, replenish with EC repeat until the EC level does not drop any further. Install the radiator cap and stop the engine.
- Replenish EC to the "MAX" line on the reservoir and leave as it is until the engine gets cool.
- After the engine gets cool, start the engine and make sure there is no water running noise heard from the heater core while the engine runs at 3,000 rpm.
- Should water running noise be heard, repeat the same procedure from the beginning.