RADIATOR (w/ EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnection the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and No. 1 engine under cover.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

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  4. REMOVE RADIATOR GRILLE


    1. A01DYIBE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the radiator grille.

    2. Remove the 2 clips and 2 screws.

    3. A01DY0N

      Detach the 6 claws and remove the radiator grille.

  5. REMOVE RADIATOR SIDE DEFLECTOR LH


    1. A01E21K

      Using a clip remover, remove the 2 clips.

    2. Detach the claw and remove the deflector.

  6. REMOVE RADIATOR SIDE DEFLECTOR RH


    1. Using a clip remover, remove the 2 clips.

    2. Detach the claw and remove the deflector.

  7. DISCONNECT RADIATOR HOSE INLET

  8. DISCONNECT RADIATOR HOSE OUTLET

  9. REMOVE FAN SHROUD

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    1. Remove the 3 bolts and oil reservoir.

    2. Disconnect the No. 1 and No. 2 water by-pass hoses from the tank upper and lower.

    3. Remove the 2 bolts and radiator reservoir.

    4. Loosen the 4 nuts holding the fluid coupling fan.

    5. Remove the drive belt Click here.

    6. Remove the 2 bolts holding the fan shroud.

    7. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the water pump.

  10. DISCONNECT NO. 1 OIL COOLER TUBE INLET (for Automatic Transmission)

  11. DISCONNECT NO. 1 OIL COOLER TUBE OUTLET (for Automatic Transmission)

  12. REMOVE RADIATOR ASSEMBLY

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    1. Remove the 4 bolts and radiator.