Hyundai Sonata: Cooling System / Radiator Repair procedures
1. |
Remove the cooling fan.
(Refer to Cooling System - "Cooling Fan") |
2. |
Loosen the drain plug, and drain the coolant. |
3. |
Remove the radiator cap to speed draining. |
4. |
Remove the radiator upper hose (A) and lowr hose (B). 

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5. |
Remove the radiator upper bracket bolts(A).
Tightening torque:
3.9 ~ 5.8 N.m (0.4 ~ 0.6 kgf.m, 2.8 ~ 4.3 lb-ft)
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6. |
Disconnect the return hose(A). 
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7. |
Remove the air guard(A) and intercooler air guard(B). 
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8. |
Loosen the radiator mounting bolts(A)
Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 10.1 Ib-ft)
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9. |
Pull the radiator (A) upward and remove it from engine room. 
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10. |
Install in the reverse order of removal.
• |
Bleed air from the cooling system. |
- |
Start engine and let it run until it warms up (until the radiator fan operates 3 or 4 times). |
- |
Turn off engine. Check the coolant level and add coolant if
needed. This will allow trapped air to be removed from the cooling
system. |
- |
Put the radiator cap on tightly, then run engine again and check for leaks. |
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Radiator Cap Testing
1. |
Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester. 
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2. |
Apply a pressure of 93.16~122.58kpa (0.95~1.25kg/cm?, 13.51~17.78psi). |
3. |
Check for a drop in pressure. |
4. |
If the pressure drops, replace the cap. |
Radiator Leakage Test
1. |
Wait until engine is cool, then carefully remove the radiator
cap and fill the radiator with engine coolant, then install a pressure
tester on it. 
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2. |
Apply a pressure of 93~123kPa (0.95~1.25kgf/cm?, 14~1
9psi). |
3. |
Inspect for engine coolant leaks and a drop in pressure. |
4. |
If the pressure drops, check hoses, the radiator and the
water pump for leakage. If there is no leakage, inspect the heater core,
the cylinder block and the cylinder head. |
5. |
Remove the tester and reinstall the radiator cap.
Check for engine oil in coolant and/or coolant in engine oil. |
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Components
1. Radiator2. Mounting insulator3. Radiator lower hose4. Radiator upper hose5. Upper mounting bracket
...
Components
1. Cooling fan controller (PWM)2. Fan motor3. Cooler fan4. Cooling fan shroud
...