Repair Procedures

Removal and Installation

1. Disconnect the battery negative terminal.

Tightening torque
(-) terminal (without battery sensor):
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
(-) terminal (with battery sensor):
4.0 - 6.0N.m (0.4 - 0.6kgf.m, 3.0 - 4.4lb-ft)

2. Remove the air cleaner assembly.
3. Remove the under covers (A).

Tightening torque:
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)




4. Loosen the drain plug and drain the coolant. Open the radiator cap to make rapid draining.

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. Remove the radiator upper hose (A) and lower hose (B).









NOTE:
Install the radiator hoses as shown illustrations.




6. Disconnect the fan connector (A) and the ATF cooler hoses (B)(A/T only).




7. Remove the front bumper.
8. Remove the rail (A) and the air guard (B).




9. Remove the cover (A).




10. Remove the upper cover (A) and the radiator mounting brackets (B).

Tightening torque :
6.9 - 10.8N.m (0.7 - 1.1kgf.m, 5.1 - 8.0lb-ft)




11. Remove the A/C condenser (A) from the radiator assembly and then lift up the radiator assembly (B).




12. Remove the cooling fan (A) from the radiator (B).




13. Installation is reverse order of removal.

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 to 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 a pressure tester on it.




2. Apply a pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2, 14 - 19psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. If the pressure drops, check hoses, the radiator and the water pump for leakage. If there is no leakage, inspect the heater core, the cylinder block and the cylinder head.
5. Remove the tester and reinstall the radiator cap.

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

Fan Motor
1. Disconnect the fan motor connector from the resistor.
2. Connect the battery voltage to the "+" terminal and ground to "-" terminal.
3. Check the cooling fan motor operates well.