Radiator: Service and Repair

RADIATOR AND RADIATOR FAN

^ Radiator





^ Radiator fan





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) Remove the collector cover.
2) Disconnect the ground cable from battery.
3) Lift up the vehicle.
4) Remove the under cover.
5) Drain engine coolant completely.
6) Disconnect the radiator outlet hose from radiator lower.





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





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





11) Remove the radiator upper brackets.





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





(2) Remove the radiator inlet hose LH from the clip.
(3) Remove the front hood cable fixing clip from the radiator stay.
(4) Remove the bolts on the left side of the radiator stay.





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





13) Disconnect the connector from radiator fan control unit.





14) Remove the reservoir tank.





15) Disconnect the radiator inlet hoses LH and RH from the radiator.





16) Disconnect the ATF radiator hose from radiator.

NOTE:
Plug the ATF pipe to prevent ATF leaks.





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





19) Remove the clip holding the ambient sensor harness.





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

INSTALLATION

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

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

3) Hold the ambient sensor harness with clip.





4) Hold the radiator and condenser with bolts.

Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)





5) Install the front bumper.
6) Connect the ATF radiator hose.

NOTE:
Use a new ATF radiator hose.





7) Connect the radiator inlet hoses LH and RH.





8) Install the reservoir tank.





9) Connect the connector to radiator fan control unit.





10) Install the radiator stay.
(1) Tighten the bolts on the right side of the radiator stay.

Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)





(2) Tighten the bolts on the left side of the radiator stay.

Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)





(3) Install the front hood cable fixing clip to the radiator stay.
(4) Install the radiator inlet hose LH to the clip.
(5) Install the latch.

Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)





11) Install the radiator upper brackets.

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





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





14) Tighten the bolts at the bottom of the radiator stay.

Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)





15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground terminal.
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) 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 of engine coolant from spurting out when removing the radiator cap tester.
^ Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

Radiator Cap

INSPECTION

1) Check that the radiator cap does not have deformation, cracks or damage.
2) Attach the radiator cap tester to radiator cap.





3) Increase pressure until the radiator cap tester gauge needle stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 - 6 seconds. Replace the radiator cap if its valve opens at less than the service limit.

Standard:
73.6 - 103.0 kPa (0.75 - 1.05 kgf/cm2, 11 - 15 psi)

Service limit:
63.6 kPa (0.65 kgf/cm2, 9 psi)

CAUTION:
Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.