Repair Procedures

Removal

1. Disconnect the battery negative terminal.
2. Remove the air cleaner assembly.
3. Remove the battery and battery tray.
4. Remove the under cover.
5. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.




6. Remove the radiator upper hose (A), lower hose (B) and then disconnect the fan motor connector(C).




7. Disconnect the ATF cooler hoses (A/T only).
8. Remove the front bumper.
9. Disconnect the over flow hose (A) from the radiator.




10. Remove the upper cover (A).
11. Remove the guide (B) and radiator mounting bracket (C).

Tightening torque:
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 7.9 lb-ft)




12. Remove the A/C high pressure pipe bracket mounting bracket (A).

Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)




13. Separate the condenser from the radiator and then remove the upper cover (A) and cooling fan assembly (B).

Tightening torque:
8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 7.9 lb-ft)




14. Pull radiator upper from engine room.
15. Installation is in the reverse order of removal.
16. 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, and 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.
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.