Radiator: Service and Repair

Radiator

Removal

WARNING: The radiator is pressurized. Wait until the engine cools down before working on the radiator.

1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.





3. Lift-up the vehicle.
4. Remove the under cover.
5. Drain the engine coolant completely.
6. Disconnect the connectors of radiator main fan motor (A) and sub fan motor (B).








7. Disconnect the ATF cooler hose from ATF pipe. (AT model) Plug the openings in the hose and radiator with caps in order to prevent ATF from leaking.





8. Disconnect the radiator outlet hose from thermostat cover.





9. Lower the vehicle.
10. Remove the air intake duct.





11. Remove the V-belt covers.





12. Disconnect the overflow hose.
13. Remove the reservoir tank.
14. Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator.








15. Remove the radiator upper brackets.





16. While lifting the radiator up, slide it to the left.
17. Lift-up the radiator, and then remove it from vehicle.

Installation
1. Attach the radiator mounting cushions to the holes on vehicle.





2. Install the radiator to vehicle.

NOTE: Fit the pins on lower side of radiator into the cushions on body side.

3. Install the radiator brackets, and then tighten the bolts.
^ Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





4. Connect the radiator inlet hose (A) and water tank hose (B).








5. Install the reservoir tank.
6. Connect the overflow hose.
7. Install the V-belt cover.





8. Install the air intake duct.
9. Lift-up the vehicle.
10. Connect the ATF cooler hoses. (AT model).





11. Connect the radiator outlet hose.





12. Connect the connectors to radiator main fan motor (A) and sub fan motor (B).








13. Install the under cover.
14. Lower the vehicle.
15. Connect the battery ground cable to battery.





16. Fill engine coolant.
17. Check the ATF level.

Inspection
1. Remove the coolant filler tank cap, top off coolant filler tank, and then attach the tester to coolant filler tank in place of cap.





2. Apply a pressure of 122 kPa (1.2 kg/cm2, 18 psi) to the coolant filler tank to check if:
^ Engine coolant leaks at/around radiator.
^ Engine coolant leaks at/around hoses or connections.

IMPORTANT:
^ Inspection must be carried out at the side of coolant filler tank, not at the side of radiator.
^ Engine should be turned off.
^ Wipe engine coolant from check points in advance.
^ Be careful to prevent engine coolant from spurting out when removing the tester.
^ Be careful also not to deform the filler neck of coolant filler tank when installing or removing tester.

Inspection
1. Attach the radiator cap to tester.





2. Increase the pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 to 6 seconds.

Coolant filler tank side
Standard pressure: 93 - 123 kPa (0.95 - 1.25 kg/cm2, 14 - 18 psi)
Service limit pressure: 83 kPa (0.85 kg/cm2, 12 psi)

Radiator side
Standard pressure: 122 - 152 kPa (1.24 - 1.55 kg/cm2, 18 - 22 psi)
Service limit pressure: 112 kPa (1.14 kg/cm2, 16 psi)

IMPORTANT:
^ Be sure to remove foreign matter and rust from the cap in advance otherwise, results of pressure test will be incorrect.
^ Do not mix up the coolant filler tank side cap with radiator side cap.