Radiator: Service and Repair

Radiator






REMOVAL

CAUTION:
The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cool 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) Remove the heat shield cover from radiator. (AT model)





6) Drain the engine coolant.
7) Disconnect the connectors of main fan motor connector (A) and sub fan motor connector (B).








8) Disconnect the radiator outlet hose from thermostat cover.





9) Disconnect the ATF cooler hoses from ATF pipes. (AT model)

NOTE:
Plug the ATF pipe to prevent ATF from leaking.





10) Lower the vehicle.
11) Remove the air intake duct.
12) Remove the reservoir tank.
13) Disconnect the radiator inlet hose (A) from the radiator.





14) Disconnect the two coolant filler tank hoses from the radiator.





15) Remove the radiator upper brackets.





16) Move the radiator to the left while lifting it upward.
17) Lift the radiator up and remove the radiator from vehicle.

INSTALLATION
1) Attach the radiator lower cushion to the hole on the radiator lower bracket.





2) Install the radiator to vehicle.

NOTE:
Make pins on the lower side of radiator be fitted into the radiator lower cushions.

3) Install the radiator upper brackets and tighten the bolts.





4) Connect the two coolant filler tank hoses to the radiator.





5) Connect the radiator inlet hose (A).





6) Install the reservoir tank.
7) Install the air intake duct.
8) Lift up the vehicle.
9) Connect the ATIF cooler hoses. (AT model)





10) Connect the radiator outlet hose.





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








12) Install the heat shield cover to the radiator. (AT model)





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





16) Fill engine coolant.
17) Check the ATF level. (AT model)

INSPECTION
1) Remove the coolant filler tank cap, fill the coolant filler tank with engine coolant, then install the tester to the installation position of the cap.





2) Apply a pressure of 122 kPa (1.2 kg/cm, 18 psi) to the radiator and check the following points:
^ Leakage from the radiator or its vicinity
^ Leakage from the hose or its connections

CAUTION:
^ 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 of the spurt of engine coolant when removing the tester.
^ Be careful not to deform the filler neck of the coolant filler tank when installing and removing the tester.