Radiator Repair Procedures

Removal and Installation

1. 1
   Remove the cooling fan. (Refer to Cooling System - "Cooling Fan")
2. 2
   Loosen the drain plug and drain the coolant.
3. 3
   Remove the radiator cap to speed up draining.
4. 4
   Remove the upper radiator hose (A) and lower hose (B).

   

   

5. 5
   Remove the radiator upper bracket bolts (A).

   Tightening torque: 3.9 ~ 5.8 N·m

   

6. 6
   Disconnect the return hose (A).

   

7. 7
   Remove the air shutter (A) and the intercooler air shutter (B).

   

8. 8
   Loosen the radiator mounting bolts (A).

   Tightening torque: 9.8 ~ 11.8 N·m

   

9. 9
   Pull the radiator (A) upward and remove it from the engine compartment.

   

10. 10
    Install in the reverse order of removal.

    Bleed air from the cooling system. Start the engine and let it run until warm (until the radiator fan cycles 3 or 4 times). Turn off the engine. Check the coolant level and add coolant if necessary. This will remove trapped air from the cooling system. Tightly close the radiator cap, then restart the engine and check for leaks.

Inspection

1. 1
   Remove the radiator cap, wet its seal with engine coolant, then install it on the pressure tester.

   

2. 2
   Apply pressure of 93.16–122.58 kPa (0.95–1.25 kgf/cm², 13.51–17.78 psi).
3. 3
   Check for pressure drop.
4. 4
   If the pressure drops, replace the radiator cap.
5. 5
   Wait until the engine cools, then carefully remove the radiator cap and fill the radiator with engine coolant, then install a pressure tester on it.

   

6. 6
   Apply a pressure of 93~123 kPa (0.95~1.25 kgf/cm², 14~19 psi).
7. 7
   Check for engine coolant leaks and pressure drop.
8. 8
   If the pressure drops, check the hoses, radiator and water pump for leaks. If there is no leak, inspect the heater core, cylinder block and cylinder head.
9. 9
   Remove the tester and install the radiator cap.

   Check for engine oil in the coolant and/or coolant in the engine oil.