Repair Procedures

Removal and Installation

1. Disconnect the battery terminals.
2. Remove the air cleaner assembly and the intercooler inlet/outlet hoses.
3. Remove the battery and battery tray.
4. Remove the under covers.
5. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
6. Disconnect the radiator upper hose (A).




7. Disconnect the lower hose (A), the fan motor connector (B) and then remove the cooling fan assembly (C).

Tightening torque :
4.9 - 7.8 N.m (0.5 - 0.8 kgf.m, 3.6 - 5.8 lb-ft)




8. Disconnect the ATF cooler hoses (A/T only).




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




10. Remove the radiator mounting brackets (A).

Tightening torque:
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)




11. Separate the condenser from the radiator and then remove the radiator assembly (A).




12. Installation is the reverse order of removal.
13. 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 - 1.25kgf/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 - 1.25kgf/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.