Removal and Installation

RADIATOR


Removal and Installation







WARNING:
Never remove the radiator cap when the engine and inverter are hot. Serious burns could occur from high pressure coolant escaping from the radiator, condenser and liquid tank assembly. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.

REMOVAL
1. Remove engine under cover.
2. Drain engine coolant from radiator, condenser and liquid tank assembly. Refer to Changing Engine Coolant.
3. Remove air cleaner duct (front). Refer to Service and Repair.
4. Remove radiator, condenser and liquid tank assembly upper hose and lower hose.
5. Remove coolant reservoir hose.
6. Drain inverter coolant from sub-radiator. Refer to Replacement.
7. Remove front bumper reinforcement. Refer to Service and Repair.
8. Remove sub radiator. Refer to Removal And Installation.
9. Discharge A/C system. Refer to Refrigeration System.
10. Remove high side junction pipe assembly. Refer to Removal And Installation For Junction Pipe.
11. Remove the refrigerant pressure sensor for installation on new radiator, condenser and liquid tank assembly. Refer to Service and Repair.
12. Remove both radiator, condenser and liquid tank assembly clips.
13. Remove radiator, condenser and liquid tank assembly.

CAUTION:
- Do not damage or scratch the radiator, condenser and liquid tank assembly and sub radiator core when removing.
- When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere.
- When installing refrigerant components to vehicle, never remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system

INSTALLATION
Installation is in the reverse order of removal.

INSPECTION

Radiator, Condenser and Liquid Tank Assembly
1. Check radiator, condenser and liquid tank assembly for mud or clogging. If necessary, clean radiator, condenser and liquid tank assembly as follows:
- Be careful not to bend or damage the radiator, condenser and liquid tank assembly fins.
- When radiator, condenser and liquid tank assembly is cleaned without removal, remove all surrounding parts such as radiator fan assembly and horns. Then tape the harness and electrical connectors to prevent water from entering.
a. Apply water by hose to the back side of the radiator, condenser and liquid tank assembly core, point the hose vertically downward.
b. Apply water again to all radiator, condenser and liquid tank assembly core surfaces once per minute.
c. Stop washing when no more dirt flows off the radiator, condenser and liquid tank assembly.
d. Blow air into the back side of radiator, condenser and liquid tank assembly core, point the air hose vertically downward.
- Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.8 in).
e. Blow air again into all the radiator, condenser and liquid tank assembly core surfaces once per minute until no water sprays out.