Repair Procedures

Removal and Installation

1. Disconnect the battery terminals.
2. Remove the air cleaner assembly.
3. Remove the under covers (A).

Tightening torque :
6.9 - 10.8N.m (0.7 - 1.1kgf.m, 5.1 - 7.9lb-ft)




4. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.

WARNING:
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

5. Disconnect the over flow hose (A) from the radiator.




6. Disconnect the radiator upper hose (A) and lower hose (B).









NOTE:
Install the radiator hoses as shown illustrations.




7. Disconnect the fan motor connector (A).




8. Disconnect the ATF oil cooler hoses (A).




9. Remove the front bumper.
10. Remove the rail (A) and the air guard (B).
11. Remove the upper cover (C) and the upper mounting bracket (D).

Tightening torque :
6.9 - 10.8N.m (0.7 - 1.1kgf.m, 5.1 - 7.9lb-ft)




12. Separate the condenser(A) from the radiator and then pull the radiator(B) upper from vehicle.




13. Remove the cooling fan assembly (A) from the radiator (B)




14. Installation is the reverse order of removal.
15. Fill the radiator with coolant and check for leaks.

NOTE:
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn off engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put the radiator cap on tightly, then run engine again and check for leaks.

Inspection

Radiator Cap Testing
1. Remove the radiator cap, wet its seal with engine coolant, then install it on a pressure tester.




2. Apply a pressure of 93.16 - 122.58kpa (0.95 - 1.25kg/cm2, 13.51 - 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Radiator Leakage Test
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester (A).




2. Apply a pressure tester to the radiator and apply a pressure of 93.16 - 122.58kpa (0.95 - 1.25kg/cm2, 13.51 - 17.78psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

NOTE:
Check for engine oil in the coolant and/or coolant in the engine oil.