Radiator: Service and Repair

RADIATOR

COMPONENTS (Part 1) (for Hatchback):

COMPONENTS (Part 2) (for Sedan):

COMPONENTS (Part 3):

COMPONENTS (Part 4) (for Automatic Transaxle):

COMPONENTS (Part 5) (for Manual Transaxle):

REMOVAL

CAUTION: Be sure that the ignition is off if you work near the electric cooling fans or radiator grille. With the ignition on the electric cooling fans may automatically start to run if the engine coolant temperature is high and/or the air conditioning is on.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT BUMPER COVER (for Hatchback)
4. REMOVE FRONT BUMPER COVER (for Sedan)





5. REMOVE AIR CLEANER ASSEMBLY

(a) Separate the intake air flow meter connector and the wire harness clamp.
(b) Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly.
(c) Separate the vacuum switching valve connector and the wire harness clamp.
(d) Separate the ventilation hose from the air cleaner hose.
(e) Release the air cleaner cap with air cleaner hose No. 1.
(f) Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and the air cleaner hose.
(g) Remove the air cleaner element.





(h) Separate the wire harness clamp from the air cleaner case.
(i) Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1.





6. REMOVE RADIATOR SUPPORT ABSORBER UPPER (for Hatchback)
(a) Disengage the 6 claws and remove the radiator support absorber upper.





7. REMOVE NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)
(a) Remove the 2 clips and No. 1 cooler cover.





8. REMOVE HOOD LOCK ASSEMBLY (w/ Theft Deterrent System)
(a) Separate the hood lock control cable assembly from the 2 clamps.





(b) Separate the engine hood courtesy switch connector.
(c) Remove the 3 bolts and remove the hood lock assembly.





9. REMOVE HOOD LOCK ASSEMBLY (w/o Theft Deterrent System)
(a) Separate the hood lock control cable assembly from the 2 clamps.





(b) Remove the 3 bolts and remove the hood lock assembly.





10. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER
(a) Separate the horn assembly connector.
(b) Remove the 4 bolts and remove the radiator support sub-assembly upper.





11. DISCONNECT RADIATOR RESERVOIR TANK HOSE
(a) Disconnect the radiator reservoir tank hose from the water filler.





12. REMOVE RADIATOR HOSE NO. 3
(a) Loosen the 2 clips and remove radiator hose No. 3.





13. DISCONNECT RADIATOR HOSE NO. 2
(a) Loosen the clip and disconnect radiator hose No. 2.





14. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler outlet hose.





15. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler inlet hose.





16. REMOVE RADIATOR ASSEMBLY (w/ Air Conditioning System)
(a) Separate the cooling fan motor connector and wire harness clamps.





(b) Disengage the 2 claws and remove the radiator assembly from the vehicle.

NOTICE: Do not apply excessive force to the cooler condenser assembly or piping when removing the radiator assembly.





17. REMOVE RADIATOR ASSEMBLY (w/o Air Conditioning System)
(a) Separate the cooling fan motor connector and wire harness clamps.
(b) Remove the radiator assembly from the vehicle.





18. REMOVE RADIATOR HOSE NO. 2
(a) Loosen the clip and remove radiator hose No. 2.





19. REMOVE OIL COOLER OUTLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and remove the cooler outlet hose.





20. REMOVE OIL COOLER INLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and remove the cooler inlet hose.





21. REMOVE FAN SHROUD
(a) Disengage the 2 claws and remove the fan shroud.





22. REMOVE RADIATOR SUPPORT CUSHION
(a) Remove the 2 radiator support cushions from the radiator assembly.





23. REMOVE RADIATOR RESERVE TANK HOSE GROMMET
(a) Remove the 2 radiator reserve tank hose grommets from the radiator assembly.





24. REMOVE RADIATOR DRAIN COCK
(a) Remove the radiator drain cock from the radiator assembly.

INSTALLATION





1. INSTALL RADIATOR DRAIN COCK
(a) Install the radiator drain cock onto the radiator assembly.





2. INSTALL RADIATOR RESERVE TANK HOSE GROMMET
(a) Install the 2 radiator reserve tank hose grommets onto the radiator assembly.





3. INSTALL RADIATOR SUPPORT CUSHION
(a) Install the 2 radiator support cushions onto the radiator assembly.





4. INSTALL FAN SHROUD
(a) Engage the 2 claws and install the fan shroud.





5. INSTALL OIL COOLER INLET HOSE (for Automatic Transaxle)
(a) Install the oil cooler inlet hose with the clip.





6. INSTALL OIL COOLER OUTLET HOSE (for Automatic Transaxle)
(a) Install the oil cooler outlet hose with the clip.





7. INSTALL RADIATOR HOSE NO. 2
(a) Install radiator hose No. 2 with the clip.





8. INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning System)
(a) Engage the 2 claws and install the radiator assembly into the vehicle.

NOTICE: Do not apply excessive force to the cooler condenser assembly or piping when installing the radiator assembly.





(b) Connect the cooling fan motor connector and wire harness clamps.





9. INSTALL RADIATOR ASSEMBLY (w/o Air Conditioning System)
(a) Install the radiator assembly into the vehicle.
(b) Connect the cooling fan motor connector and wire harness clamps.





10. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)
(a) Connect the oil cooler inlet hose with the clip.





11. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)
(a) Connect the oil cooler outlet hose with the clip.





12. CONNECT RADIATOR HOSE NO. 2
(a) Connect radiator hose No. 2 with the clip.





13. INSTALL RADIATOR HOSE NO. 3
(a) Install radiator hose No. 3 with the 2 clips.





14. CONNECT RADIATOR RESERVOIR TANK HOSE
(a) Connect the radiator reservoir tank hose to the water filler.





15. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER
(a) Install the radiator support sub-assembly upper with the 4 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
(b) Connect the horn assembly connector.





16. INSTALL HOOD LOCK ASSEMBLY (w/ Theft Deterrent System)
(a) Temporarily install the hood lock assembly with the 3 bolts.
(b) Connect the engine hood courtesy switch connector.





(c) Connect the hood lock control cable assembly to the 2 clamps.





17. INSTALL HOOD LOCK ASSEMBLY (w/o Theft Deterrent System)
(a) Temporarily install the hood lock assembly with the 3 bolts.





(b) Connect the hood lock control cable assembly to the 2 clamps.





18. INSTALL NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)
(a) Insert the 2 pins of No. 1 cooler cover into the radiator support LWR.
(b) Install No. 1 cooler cover with the 2 clips.





19. INSTALL RADIATOR SUPPORT ABSORBER UPPER (for Hatchback)
(a) Engage the 6 claws and install the radiator support absorber upper.





20. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
(b) Connect the wire harness to the air cleaner case.
(c) Install the air cleaner element.





(d) Install and lock the air cleaner cap and air cleaner hose and then tighten the air cleaner hose clamp.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
(e) Connect the ventilation hose to the air cleaner hose.
(f) Connect the vacuum switching valve connector and wire harness clamp.
(g) Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly.
(h) Connect the intake air flow meter connector and wire harness clamp.

21. INSTALL FRONT BUMPER COVER (for Hatchback)
22. INSTALL FRONT BUMPER COVER (for Sedan)
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

24. ADD ENGINE COOLANT





25. ADJUST HOOD LOCK ASSEMBLY
(a) Loosen the 3 bolts.
(b) Adjust the hood lock position so that the striker can enter it smoothly.
(c) Tighten the 3 bolts after the adjustment.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

26. CHECK FOR ENGINE COOLANT LEAKAGE