Repair Procedures

Inspection

Radiator Cap Test
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.




2. Apply a pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2, 14 - 19psi)
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.




2. Apply a pressure tester to the radiator and apply a pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2 14 - 18 psi).
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.

Removal

1. Remove the drain plug and drain the engine coolant.




2. Disconnect the breather hose (A), vacuum hose (B) and remove the air duct (C), air cleaner assembly (D).

Tightening torque :
Bolt : 7.8 - 9.8N.m (0.9 - 1.1kgf.m, 5.8 - 7.2lb-ft)
Clamp : 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.1 - 3.6lb-ft)




3. Remove the radiator upper hose (A).




4. Disconnect the intercooler inlet hose (A), radiator lower hose (B).

Tightening torque :
Bolt : 14.7 - 19.6N.m (1.5 - 2.0kgf.m, 10.8 - 14.4lb-ft)
Clamp : 4.9 - 6.8N.m (0.5 - 0.7kgf.m, 3.6 - 5.0lb-ft)




5. Disconnect the BPS connector (A) and intercooler outlet hose (B).




6. Remove the radiator.
(1) Remove the cooling fan connector(A).
(2) Remove the reservoir tank(B).
(3) Remove the fan assembly(C).
(4) Remove the radiator after removing the radiator upper mounting bracket(D).




7. Installation is the reverse of removal.
8. Fill the engine coolant.
9. Start the engine and check for leaks.
10. Recheck the coolant level.