Radiator: Service and Repair

RADIATOR AND RADIATOR FAN





REMOVAL

WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator.

1) Set the vehicle on a lift.
2) Remove the collector cover.
3) Disconnect the ground cable from the battery.
4) Lift up the vehicle.
5) Remove the under cover.
6) Drain engine coolant completely.
7) Disconnect the radiator outlet hose from radiator.





8) Remove the bolts on the underside of the radiator stay.





9) Lower the vehicle.
10) Remove the air intake duct.
11) Remove the front upper cover.





12) Remove the radiator upper brackets.





13) Remove the radiator stay.
(1) Remove the latch.





(2) Remove the radiator hose bracket.
(3) Remove the clip holding the harness.
(4) Remove the bolts on the left side of the radiator stay.





(5) Remove the bolts on the right side of the radiator stay.





14) Disconnect the connector from radiator fan control unit.





15) Remove the reservoir tank.





16) Disconnect the radiator hose from radiator.





17) Disconnect the ATF cooler hose from the radiator.

NOTE: Plug the ATF pipe to prevent ATF leaks.





18) Remove the front bumper.
19) Remove the bolts which hold the radiator and condenser.





20) Remove the clip holding the ambient sensor harness.





21) Lift the radiator up and away from vehicle.
22) Remove the radiator lower cushion.

INSTALLATION
1) Install the radiator lower cushion to the vehicle.
2) Install the radiator to vehicle.

NOTE: Insert the pins on the lower side of radiator into the radiator lower cushions on the vehicle side.

3) Hold the harness of the ambient sensor with a clip.





4) Hold the radiator and condenser with bolts.
Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)





5) Install the front bumper.
6) Connect the ATF cooler hoses.





7) Connect the radiator hose.





8) Install the reservoir tank.





9) Connect the connector to radiator fan control unit.





10) Install the radiator stay.
(1) Install the latch.
Tightening torque: 33 N-m (3.4 kgf-m, 25 ft-lb)





(2) Install the radiator hose bracket.
(3) Hold the harness to the radiator stay with a clip.
(4) Tighten the bolts on the left side of the radiator stay.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)





(5) Tighten the bolts on the right side of the radiator stay.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)





11) Install the radiator upper brackets.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)





12) Lift up the vehicle.
13) Connect the radiator outlet hose.





14) Tighten the bolts on the lower side of the radiator stay.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)





15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground cable to the battery.
18) Fill engine coolant.
19) Check the ATF level and replenish it if necessary.
20) Install the front upper cover.
21) Install the air intake duct.
22) Install the collector cover.

INSPECTION
1) Remove the radiator cap, fill the radiator with engine coolant, and then install the tester to the installation position of cap.





2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to the radiator and check the following points:
^ Leakage from the radiator or its vicinity
^ Leakage from the hose or its connections

CAUTION:
^ Engine should be turned off.
^ Wipe engine coolant from check points in advance.
^ Be careful of the spurt of engine coolant when removing the tester.
^ Be careful not to deform the filler neck of radiator when installing and removing the tester.