Hyundai Sonata: Cooling System / Radiator Repair procedures

Removal and Installation

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).

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)

6.	Disconnect the return hose(A).

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

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)

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

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.

Inspection

Radiator Cap Testing

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

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.

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.

Remove the tester and reinstall the radiator cap.

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

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