Radiator: Service and Repair

Radiator

REMOVAL

CAUTION:
The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cool down before working on the radiator.

1) Disconnect the ground cable from battery.





2) Lift up the vehicle.
3) Remove the under cover.
4) Drain engine coolant.
5) Disconnect the radiator outlet hose from thermostat cover.





6) Disconnect the CVTF radiator hose from the CVTF pipe. (CVT model)

NOTE:
Plug the CVTF pipe to prevent CVTF from leaking.





7) Lower the vehicle.
8) Remove the air intake duct.
9) Remove the reservoir tank.
10) Disconnect the connector (A) from the main fan motor and the connector (B) from the sub fan motor.








11) Disconnect the radiator inlet hoses from the engine.





12) Remove the grille bracket.

NOTE:
Remove ten clips when removing the grille bracket.





13) Remove the radiator upper brackets.





14) Lift the radiator up and away from vehicle.
15) Remove the radiator lower cushion from the vehicle body.





INSTALLATION

1) Install the radiator lower cushion to the vehicle body.





2) Install the radiator to vehicle.

NOTE:
Make pins on the lower side of radiator be fitted into the radiator lower cushions.

3) Install the radiator upper brackets.

Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)





4) Attach the grille bracket.





5) Connect the radiator inlet hose.





6) Connect the connector (A) to the radiator main fan motor and the connector (B) to the sub fan motor connector.








7) Install the air intake duct.
8) Install the reservoir tank.
9) Lift up the vehicle.
10) Connect the CVTF radiator hose. (CVT model)

NOTE:
Use a new CVTF radiator hose.





11) Connect the radiator outlet hose.





12) Install the under cover.
13) Lower the vehicle.
14) Connect the battery ground terminal.





15) Fill engine coolant.
16) Adjust the CVTF level. (CVT model)

INSPECTION

1) Check that the radiator does not have deformation, cracks or damage.
2) Check that the hose has no cracks, damage or loose part.
3) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.





4) Apply a pressure of 157 kPa (1.6 kgf/cm2, 23 psi) to the radiator, and check the following items.
^ 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 not to deform the filler neck of radiator when installing and removing the radiator cap tester.
^ Be careful of engine coolant from spurting out when removing the radiator cap tester.