Radiator: Service and Repair

Radiator





REMOVAL

CAUTION:
The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cools down before working on the radiator.

1) Remove the collector cover.
2) Disconnect the ground cable from battery.





3) Lift up the vehicle.
4) Remove the under cover.
5) Drain engine coolant.
6) Disconnect the radiator outlet hose from thermostat cover.





7) Lower the vehicle.
8) Remove the air intake duct.
9) Remove the reservoir tank.
10) Disconnect the connectors of main fan motor connector (A) and sub fan motor connector (B).








11) Disconnect the radiator inlet hose from the water tank pipe.





12) Remove the grille bracket.

NOTE:
Remove ten clips when removing the grille bracket.





13) Remove the radiator upper brackets.





14) Lift the radiator up and remove the radiator from vehicle.
15) Remove the radiator lower cushion from the vehicle body.





INSTALLATION
1) Install the radiator lower cushion to the vehicle body.





2) Install the radiator to the vehicle.

NOTE:
Insert the pin on the lower side of radiator into the radiator lower cushion.

3) Install the radiator upper brackets.





4) Attach the grille bracket.





5) Connect the radiator inlet hose.





6) Connect the connectors of main fan motor connector (A) and sub fan motor connector (B).








7) Install the reservoir tank.
8) Install the air intake duct.
9) Lift up the vehicle.
10) Connect the radiator outlet hose.





11) Install the under cover.
12) Lower the vehicle.
13) Connect the ground cable to battery.





14) Fill engine coolant.
15) Install the collector cover.

INSPECTION
1) Check that the radiator does not have deformation, cracks or damage.
2) Check that the hose has no cracks, damage or loose part.
3) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.





4) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to the radiator and check the following points:
^ Leakage from the radiator or its vicinity
^ Leakage from the hose or its connections

CAUTION:
^ Engine should be turned off.
^ Wipe engine coolant from check points in advance.
^ Be careful of the spurt of engine coolant when removing the radiator cap tester.
^ Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.