RADIATOR INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. INSTALL LOWER RADIATOR SUPPORT


    1. Install the 2 lower radiator supports to the radiator assembly.

  2. INSTALL SUB-RADIATOR SUPPORT CUSHION


    1. Install the 2 sub-radiator support cushions to the radiator assembly.

  3. INSTALL FAN WITH MOTOR ASSEMBLY


    1. B006GJO

      Attach the guide.

    2. Install the fan with motor assembly to the radiator assembly with the 2 bolts.

      Note

      Do not damage the radiator assembly when installing the fan with motor assembly.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL NO. 5 RADIATOR TO SUPPORT SEAL


    1. Install a new No. 5 radiator support to seal to the radiator assembly.

  5. INSTALL NO. 4 RADIATOR TO SUPPORT SEAL


    1. Install a new No. 4 radiator support to seal to the radiator assembly.

  6. INSTALL NO. 3 RADIATOR TO SUPPORT SEAL


    1. Install a new No. 3 radiator support to seal to the radiator assembly.

  7. INSTALL NO. 2 RADIATOR TO SUPPORT SEAL


    1. Install a new No. 2 radiator support to seal to the radiator assembly.

  8. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL


    1. Upper Side:


      1. Install a new No. 1 radiator support to seal to the radiator assembly.

    2. Lower Side:


      1. Install a new No. 1 radiator support to seal to the radiator assembly.

  9. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. B006E08

      Attach the claw to install the rear radiator side air guide plate RH to the radiator assembly.

  10. INSTALL NO. 2 RADIATOR HOSE


    1. Install the No. 2 radiator hose to the radiator assembly, and slide the clip to secure the hose.

      Note

      Install so that the No. 2 radiator hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamp to install the No. 2 radiator hose with the No. 4 radiator hose and water inlet hose.

      B006DFXC01
      *1 No. 2 Radiator Hose *2 No. 4 Radiator Hose
      *3 Water Inlet Hose - -
      *a View A *b 120°
      *c 18° *d Paint Mark
      *e Upper Side *f LH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 5 mm (0.0787 to 0.197 in.) *n 0 to 1 mm (0 to 0.0394 in.)

  11. INSTALL NO. 1 RADIATOR HOSE


    1. Install the No. 1 radiator hose to the radiator assembly, and slide the clip to secure the hose.

      Note

      Install so that the No. 1 radiator hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamps to install the No. 1 radiator hose with the No. 3 radiator hose.

      B006GJ5C01
      *1 No. 1 Radiator Hose *2 No. 3 Radiator Hose
      *a View A *b 120°
      *c 18° *d Paint Mark
      *e Upper Side *f LH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 5 mm (0.0787 to 0.197 in.) *n 0 to 1 mm (0 to 0.0394 in.)

  12. INSTALL INTERCOOLER COOLING RADIATOR ASSEMBLY

    Click here

  13. INSTALL INTERCOOLER COOLING WATER HOSE ASSEMBLY


    1. Connect the intercooler water hose assembly, and slide the clips to secure the hose to the intercooler cooling radiator assembly.

      Note


      • Install so that the intercooler water hose assembly paint mark and intercooler cooling radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the intercooler water hose assembly is securely inserted to the stopper. (Axial Direction)

      B006GGGC01
      *a View A *b 90°
      *c Paint Mark *d Lower Side
      *e RH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)
    2. B006ET9

      Install the intercooler water hose assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Attach the clamp.

  14. INSTALL DISCHARGE HOSE SUB-ASSEMBLY


    1. Attach the clamp to install the discharge hose sub-assembly to the fan with motor assembly.

  15. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. B006FU5

      Attach the claw and install the rear radiator side air guide plate LH to the radiator assembly.

  16. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly together with the intercooler cooling radiator assembly and fan with motor assembly to the vehicle.

      Note


      • Perform the following procedure with 2 or more people to prevent damage to the radiator assembly.


      • Do not damage the radiator assembly, fan with motor assembly, cooler pipe or cooling hoses when installing them.

      B006ABWC01
      B006DHE Install in this Direction - -

  17. INSTALL NO. 1 RADIATOR AIR GUIDE LH


    1. Install the No. 1 radiator air guide LH with the 5 clips.

  18. INSTALL NO. 1 RADIATOR AIR GUIDE RH


    1. Install the No. 1 radiator air guide RH with the 5 clips.

  19. INSTALL COOLER CONDENSER ASSEMBLY


    1. Insert the cooler condenser assembly into the vehicle and attach the guide.

      Note

      When inserting the cooler condenser assembly, do not damage the cooler condenser assembly and radiator assembly.

    2. Attach the claw to install the cooler condenser assembly.

      B006EXGC01
      B006DHE Install in this Direction - -

  20. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    • Compressor with Pulley Assembly Side: (for 2WD)

      Click here

    • Compressor with Pulley Assembly Side: (for AWD)

      Click here

    • Cooler Condenser Assembly Side:

      Click here

  21. CONNECT LIQUID TUBE SUB-ASSEMBLY A

    Click here

  22. CONNECT NO. 2 INTERCOOLER COOLING WATER HOSE


    1. Connect the No. 2 intercooler cooling water hose, and slide the clips to secure the hose to the intercooler cooler water hose assembly.

      Note


      • Install so that the No. 2 intercooler cooling water hose paint mark and intercooler cooler water hose assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the No. 2 intercooler cooling water hose is securely inserted to the stopper. (Axial Direction)

      B006F6MC01
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e Rear Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

  23. CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE


    1. Connect the No. 1 intercooler cooling water hose, and slide the clips to secure the hose to the intercooler cooler water hose assembly.

      Note


      • Install so that the No. 1 intercooler cooling water hose paint mark and intercooler cooler water hose assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the No. 1 intercooler cooling water hose is securely inserted to the stopper. (Axial Direction)

      B006CEZC01
      *a View A *b 120°
      *c 22.6° *d Paint Mark
      *e Front Side *f RH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 7 mm (0.0787 to 0.276 in.) - -

  24. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the upper radiator support sub-assembly with the 4 bolts.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

  25. INSTALL HOOD LOCK CONTROL CABLE COVER LH (for LHD)


    1. Attach the clamp to connect the hood lock control cable cover LH.

    2. Install the screw.

  26. INSTALL HOOD LOCK CONTROL CABLE COVER RH


    1. Attach the clamp to connect the hood lock control cable cover RH.

    2. Install the screw.

  27. CONNECT ENGINE ROOM MAIN WIRE


    1. Attach the clamps to connect the engine room main wire.

    2. Connect the connector.

  28. INSTALL HOOD LOCK SUPPORT BRACE


    1. Install the hood lock support brace with the 2 bolts.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Attach the clamps.

  29. CONNECT INTERCOOLER COOLING WATER OUTLET HOSE


    1. Connect the intercooler cooling water outlet hose, and slide the clips to secure the hose to the water tube.

      Note


      • Install so that the intercooler cooling water outlet hose paint mark and water tube positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the intercooler cooling water outlet hose is securely inserted to the stopper. (Axial Direction)

      B006G54C01
      *a View A *b 120°
      *c Paint Mark *d Front Side
      *e LH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

  30. CONNECT WATER INLET HOSE


    1. Connect the water inlet hose, and slide the clips to secure the hose to the water tube.

      Note


      • Install so that the water inlet hose paint mark and oil cooler assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the water inlet hose is securely inserted to the stopper. (Axial Direction)

    2. Attach the clamp.

      B006GSBC01
      *a View A *b 120°
      *c Paint Mark *d Rear Side
      *e LH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

  31. CONNECT NO. 4 RADIATOR HOSE


    1. Connect the No. 4 radiator hose to the water inlet assembly, and slide the clip to secure the hose.

      Note

      Install so that the No. 4 radiator hose paint mark and water inlet assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamp.

      B006A5UC01
      *a View A *b 120°
      *c 45.4° *d Paint Mark
      *e Upper Side *f RH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 6 mm (0.0787 to 0.236 in.) *n 0 to 1 mm (0 to 0.0394 in.)

  32. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the water control valve, and slide the clip to secure the hose.

      Note

      Install so that the No. 3 radiator hose paint mark and water control valve positioning stopper are securely overlapped. (Rotational Direction)

      B006EKTC01
      *a View A *b 120°
      *c 32.1° *d Paint Mark
      *e Upper Side *f LH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 6 mm (0.0787 to 0.236 in.) *n 0 to 1 mm (0 to 0.0394 in.)

  33. CONNECT NO. 3 TRANSMISSION OIL COOLER HOSE (w/ In-tank Oil Cooler)


    1. Connect the No. 3 transmission oil cooler hose to the radiator assembly, and slide the clip to secure the hose.

    2. Attach the clamp.

  34. CONNECT NO. 1 OIL COOLER OUTLET HOSE (w/ In-tank Oil Cooler)


    1. Connect the No. 1 oil cooler outlet hose to the radiator assembly, and slide the clip to secure the hose.

    2. Attach the clamp.

  35. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY


    1. B006GFK

      Install the intercooler reserve tank assembly to the fan with motor assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. for 2WD:


      1. Connect the water by-pass hose to the electric water pump assembly, and slide the clip to secure the hose.

        Note


        • Install so that the water by-pass hose paint mark and electric water pump assembly positioning stopper are securely overlapped. (Rotational Direction)

        • Make sure the water by-pass hose is securely inserted to the stopper. (Axial Direction)

        B006BHIC01
        *1 Water By-pass Hose - -
        *a View A *b 120°
        *c Paint Mark *d Front Side
        *e RH Side *f Rotational Direction
        *g OK *h NG
        *i Variation Range *j Axis Direction
        *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

    3. for AWD:


      1. Connect the water by-pass hose to the electric water pump assembly, and slide the clip to secure the hose.

        Note


        • Install so that the water by-pass hose paint mark and electric water pump assembly positioning stopper are securely overlapped. (Rotational Direction)

        • Make sure the water by-pass hose is securely inserted to the stopper. (Axial Direction)

        B006BP7C01
        *1 Water By-pass Hose - -
        *a View A *b 120°
        *c Paint Mark *d Front Side
        *e RH Side *f Rotational Direction
        *g OK *h NG
        *i Variation Range *j Axis Direction
        *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

    4. Connect the intercooler reserve tank hose, and slide the clips to secure the hose to the intercooler reserve tank assembly.

      Note


      • Install so that the intercooler reserve tank hose paint mark and intercooler reserve tank assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the intercooler reserve tank hose is securely inserted to the stopper. (Axial Direction)

      B006EI7C01
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e Front Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

  36. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. B006B7VC01
      B006AHR Bolt
      B006EC9 Clip

      Install the radiator reserve tank assembly to the fan with motor assembly with the 2 bolts and clip.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Connect the reserve tank outlet hose, and slide the clip to secure the hose to the radiator pipe.

      Note


      • Install so that the reserve tank outlet hose paint mark and radiator pipe positioning stopper are securely overlapped.

      • Make sure the reserve tank outlet hose is securely inserted to the stopper. (Axial Direction)

      B006CJ5C01
      *1 Radiator Pipe - -
      *a 120° or less *b 14.5°
      *c Fit the claw of the clip in the following range. *d Paint Mark
      *e Stopper *f 2 to 5 mm (0.0787 to 0.197 in.)
    3. B006ESM

      Connect the connectors and attach the clamps.

    4. Connect the radiator reserve tank hose, and slide the clip to secure the hose to the radiator assembly.

      Note


      • Install so that the radiator reserve tank hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

      • Make sure the radiator reserve tank hose is securely inserted to the stopper. (Axial Direction)

      B006EWAC01
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e LH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)

  37. INSTALL HIGH PITCHED HORN ASSEMBLY

    Click here

  38. INSTALL LOW PITCHED HORN ASSEMBLY

    Click here

  39. INSTALL HOOD LOCK ASSEMBLY

    Click here

  40. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  41. INSTALL AIR CLEANER SUPPORT BRACKET

    Click here

  42. CONNECT NO. 3 ENGINE ROOM WIRE

    Click here

  43. INSTALL FRONT BUMPER NO. 2 REINFORCEMENT SUB-ASSEMBLY

    Click here

  44. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here

  45. INSTALL HEADLIGHT ASSEMBLY LH

    Click here

  46. INSTALL HEADLIGHT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  47. INSTALL FRONT BUMPER ENERGY ABSORBER SUB-ASSEMBLY

    Click here

  48. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH

    Click here

  49. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH

    Click here

  50. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  51. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  52. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH

    Click here

  53. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH

    Click here

  54. INSTALL FRONT BUMPER


  55. ADD ENGINE COOLANT

    Click here

  56. ADD COOLANT (for Intercooler)

    Click here

  57. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  58. INSPECT FOR COOLANT LEAK

    Click here

  59. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  60. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  61. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  62. INSTALL RADIATOR COVER PLATE

    Click here

  63. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  64. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for AWD)

    Click here

  65. INSTALL FRONT SUSPENSION MEMBER BRACE (for AWD)

    Click here

  66. INSTALL OIL PAN PROTECTOR (for 2WD)

    Click here

  67. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


  68. INSPECT FOR COOLING FAN MOTOR

    Click here

  69. ADJUST HEADLIGHT AIMING

    Click here