Removal and Replacement

RADIATOR

COMPONENTS:

REMOVAL
1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE NO. 1 INLET AIR CLEANER
6. DISCONNECT NO. 2 VENTILATION HOSE
7. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
8. REMOVE ENGINE UNDER COVER
9. DRAIN ENGINE COOLANT
10. REMOVE FRONT BUMPER ASSEMBLY
11. REMOVE FRONT BUMPER ENERGY ABSORBER

12. REMOVE RADIATOR SUPPORT OPENING COVER
a. Disengage the 2 clips and remove the radiator support opening cover.
13. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/Dynamic Radar Cruise Control System)

14. REMOVE HOOD LOCK CONTROL CABLE COVER
a. Remove the 3 screws, clamp and the hood lock control cable cover.
15. DISCONNECT HOOD LOCK ASSEMBLY

a. Disconnect the connector.

b. Remove the hood lock nut cap and the hood lock nut.
c. Remove the 2 bolts, and separate the hood lock assembly from the upper radiator support.

NOTICE: Do not forcibly bend the hood lock control cable.

16. REMOVE UPPER RADIATOR SUPPORT

a. Separate the 4 wire harness clamps and the 3 connectors.

b. Separate the clamp and the cooling fan motor connector.

c. Separate the clamp and the No. 2 cooling fan motor connector.

d. Separate the 6 clamps and the No. 2 engine room wire.

e. Remove the 5 bolts and the upper radiator support.

17. REMOVE RADIATOR INLET HOSE
a. Remove the 2 clips and the radiator inlet hose from the radiator assembly.

18. REMOVE RADIATOR OUTLET HOSE
a. Remove the 2 clamps and the radiator outlet hose from the radiator assembly.

19. SEPARATE COOLER CONDENSER ASSEMBLY
a. Remove the 4 bolts, separate the cooler condenser assembly from the radiator assembly.

20. REMOVE ENGINE ROOM ECU OUTLET DUCT
a. Remove the engine room ECU outlet duct from the engine room ECU box.

21. REMOVE RESERVE TANK CAP SUB-ASSEMBLY
a. Separate the reserve tank cap sub-assembly from the reserve tank.
22. REMOVE RADIATOR ASSEMBLY

a. Remove the radiator assembly from the vehicle together with the cooling fan assembly.

NOTICE: Make sure that the cooler condenser assembly and radiator assembly do not come into contact with each other.

b. Remove the 3 claws and the cooling fan assembly from the radiator assembly.

c. Remove the 2 radiator support cushions and the 2 lower radiator supports.

DISASSEMBLY
1. ASSEMBLE SST
SST 09230-01010

a. Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.

NOTICE: If this adjustment is not performed, the claw will be damaged.

Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 inch)
2. UNCAULK LOCK PLATE
SST 09230-01010 (09231-01010, 09231-01030)

a. Using SST to release the caulking, grip the handle until it is stopped by the stopper bolt.

3. REMOVE RADIATOR UPPER TANK AND LOWER TANK
a. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic hammer and remove the tank.
b. Remove the O-ring.

4. INSPECT LOCK PLATE FOR DAMAGE
Inspect the lock plate for damage.

HINT:
^ If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any deformations with pliers.
^ Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.

NOTICE:
The radiator assembly can be recaulked only twice.
After the 2nd time, the radiator core must be replaced.

REASSEMBLY

1. INSTALL RADIATOR UPPER TANK AND LOWER TANK
a. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure that the O-ring is not twisted.

HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.

b. Tap the lock plate with a plastic hammer so that there is no gap between the lock plate and tank.
2. ASSEMBLE SST
SST 09230-01010, 09231-14010

a. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.
Dimension B: 8.4 mm (0.331 inch)
3. CAULK LOCK PLATE
SST 09230-01010

a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until it is stopped by the stopper bolt.

b. Do not tap the areas protruding around port (1), claws (2) and grooves (3).

c. The points shown in the illustration cannot be tapped with SST Use pliers and be careful not to damage the core plates.

d. Check lock plate height (H) after completing caulking.
4. CHECK FOR WATER LEAKS
SST 09230-01010

a. Plug the inlet and outlet pipes of the radiator with SST
b. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)

NOTICE: Do not apply more than 177 kPa (1.8 kgf/cm2, 26 psi) to the radiator.

c. Submerge the radiator in water.

d. Check for leaks.

HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Before doing the water leak test, first shake the radiator in the water until air bubbles disappear.

INSTALLATION
1. INSTALL RADIATOR ASSEMBLY

a. Install the 2 radiator support cushions and the 2 lower radiator supports to the radiator assembly.

b. Install the cooling fan assembly to the radiator assembly by engaging them at the bottom. Engage the 3 claws to secure the cooling fan assembly to the radiator assembly.

c. Install the radiator assembly to the vehicle together with the cooling fan assembly.

NOTICE: Make sure that the cooler condenser assembly and radiator assembly do not come into contact with each other.

2. INSTALL RESERVE TANK CAP SUB-ASSEMBLY
a. Install the reserve tank cap sub-assembly to the reserve tank.

3. INSTALL ENGINE ROOM ECU OUTLET DUCT
a. Install the engine room ECU outlet duct to the engine room ECU box.

4. INSTALL COOLER CONDENSER ASSEMBLY
a. Install the 4 bolts and the cooler condenser assembly to the radiator assembly.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

5. INSTALL RADIATOR OUTLET HOSE
a. Install the radiator outlet hose to the radiator assembly and secure it with the clips.

HINT:
^ Make sure that the claws on the clips are facing downward.
^ Dimension a in the illustration (between the hose end and the clip end) should be less than 1.0 - 5.0 mm.
^ Connect the hose until it makes contact with the stopper. (Dimension b should be less than 2.5 mm).

6. INSTALL RADIATOR INLET HOSE
a. Install the radiator inlet hose to the radiator assembly and secure it with the clips.

HINT:
^ Make sure that the claws on the clips are positioned as shown in the illustration.
^ Dimension a in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.
^ Connect the hose until it makes contact with the stopper. (Dimension b should be less than 2.5 mm).

7. INSTALL UPPER RADIATOR SUPPORT

a. Install the 5 bolts and the upper radiator support.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

b. Install the 6 wire harness clamps and the No. 2 engine room wire.

c. Connect the clamp and the No. 2 cooling fan motor connector.

d. Connect the clamp and the cooling fan motor connector.

e. Connect the 4 wire harness clamps and the 3 connectors.
8. INSTALL HOOD LOCK ASSEMBLY

a. Install the 2 bolts and the hood lock assembly to the upper radiator support.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
b. Install the hood lock nut and the hood lock nut cap.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

c. Connect the connector.

9. INSTALL HOOD LOCK CONTROL CABLE COVER
a. Connect the clamp, and install the 3 screws and the hood lock control cable cover.
10. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/Dynamic Radar Cruise Control System)
11. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
12. CONNECT NO. 2 VENTILATION HOSE
13. INSTALL NO. 1 INLET AIR CLEANER

14. INSTALL RADIATOR SUPPORT OPENING COVER
a. Connect the 2 clips, and install the radiator support opening cover.
15. INSTALL FRONT BUMPER ENERGY ABSORBER
16. INSTALL FRONT BUMPER ASSEMBLY
17. ADD ENGINE COOLANT
18. CHECK FOR ENGINE COOLANT LEAKAGE
19. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY
20. PUT VEHICLE UNDER THESE CONDITIONS
a. Adjust the tire pressure to the correct value range.
b. Start the engine and charge the battery.
21. FOG LIGHT AIMING ADJUSTMENT
22. FOG LIGHT AIMING INSPECTION
23. INSTALL ENGINE UNDER COVER
24. INSTALL V-BANK COVER SUB-ASSEMBLY
25. INSTALL ENGINE ROOM SIDE COVER LH
26. INSTALL ENGINE ROOM SIDE COVER RH
27. INSTALL COOL AIR INTAKE DUCT SEAL