Hyundai Tucson: Cooling System / Radiator Repair procedures

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 93.16~122.58 kPa (0.95~1.25 kgf/cmx, 13.51~17.78 psi).
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 it on the pressure tester.

2.
Apply a pressure tester to the radiator and apply a pressure of 93.16~122.58 kPa (0.95~1.25 kgf/cmx, 13.51~17.78 psi).
3.
Inspect for engine coolant leaks and a drop in pressure.
4.
Remove the tester and reinstall the radiator cap.
   
Check for engine oil in the coolant and/or coolant in the engine oil.
Removal and Installation
1.
Disconnect the battery negative terminal.
2.
Remove the air cleaner assembly.
(Refer to Intake and exhaust system in this group)
3.
Remove the under cover (A).

Tightening torque:
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)

4.
Loosen the drain plug (A), and drain the coolant.
Remove the radiator cap to speed draining.

   
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
5.
Remove the radiator upper hose (A).

6.
Remove the radiator lower hose (A).

7.
Disconnect the fan motor connector (A) and then remove the cooling fan assembly.

Tightening torque:
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 7.9 lb-ft)

8.
Remove the front bumper.
(Refer to Body - "Front Bumper")
9.
Disconnect the over flow hose (A) from the radiator.

10.
Remove the cover (A) and the air guard (B) and then separate the condenser from the radiator.

11.
Remove the radiator mounting bracket (A) and then pull the radiator upper from vehicle.

Tightening torque:
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 7.9 lb-ft)

12.
Installation is in the reverse order of removal.
13.
Fill the radiator with coolant and check for leaks.
   
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 and let it cool dwon. 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.
Radiator Components and Components Location
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