Removal and Installation

RADIATOR

Removal and Installation


REMOVAL


WARNING:
Never remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine coolant escaping from water outlet (front). Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
1.Remove the following parts:
- Engine under cover, using a power tool.
- Engine cover: Refer to "Exploded View" Exploded View.
- Air cleaner case (RH and LH): Refer to "Exploded View" Exploded View.
- Reservoir tank: Refer to "Exploded View" Exploded View.
- Hood lock cover, hood lock stay assembly and horn: Refer to "Exploded View" Exploded View.
2.Remove condenser. Refer to "Exploded View" Exploded View.
3.Drain engine coolant from radiator. Refer to "Draining" Draining Engine Coolant.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belt.
4.Disconnect A/T fluid cooler hoses from radiator.
5.Remove radiator hoses (upper and lower) and reservoir tank hose.

CAUTION:
- Never allow engine coolant to contact drive belt.





- Never loosen radiator water inlet pipe mounting screw (A). If loosened, replace radiator (1).





6.Remove cooling fan assembly. Refer to "Exploded View" Exploded View.

CAUTION:
Never damage or scratch radiator core when removing.





7.Rotate two radiator upper mount brackets 90 degrees in direction as shown in the figure, and remove them.





8.Remove radiator as follows:

CAUTION:
Never damage radiator core.





a.Lift up and pull the radiator (1) forward, and then remove the mounting rubber (lower) (3) from the radiator core support (2).










b.Remove radiator (1) from front of radiator core support (2).






INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:
- Do not reuse O-rings.
- Replace water hose clamp if it is removed.
- Use genuine mounting bolts for the cooling fan assembly and strictly observe the tightening torque.
(Breakage prevention for radiator)
NOTE:
- Insert the radiator hose (1) all the way to the stopper (2) or by 33 mm (1.30 in) (hose without a stopper).










- For the orientation of the hose clamp pawl, refer to the figure.




















- The angle (b) created by the hose clamp pawl and the specified line (A) must be within �
30� as shown in the figure.





- To install hose clamps (1), check that the dimension (A) from the end of the paint mark (2) on the radiator hose to the hose clamp is within the reference value.