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 NO. 5 RADIATOR TO SUPPORT SEAL


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

  2. INSTALL NO. 4 RADIATOR TO SUPPORT SEAL


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

  3. INSTALL NO. 3 RADIATOR TO SUPPORT SEAL


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

  4. INSTALL NO. 2 RADIATOR TO SUPPORT SEAL


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

  5. 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.

  6. INSTALL LOWER RADIATOR SUPPORT


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

  7. INSTALL SUB-RADIATOR SUPPORT CUSHION


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

  8. INSTALL FAN WITH MOTOR ASSEMBLY


    1. B006F12

      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 }

  9. INSTALL NO. 2 RADIATOR HOSE


    1. Install the No. 2 radiator hose with No. 3 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)

      Tech Tips

      The clip may be installed facing either up or down.

    2. Attach the clamp.

      B006G95C01
      *1 No. 2 Radiator Hose *2 No. 3 Radiator Hose
      *a View A *b 120°
      *c 18° *d Paint Mark
      *e Fan Shroud Side Rib *f Upper Side
      *g LH Side *h Rotational Direction
      *i OK *j NG
      *k Variation Range *l Axis Direction
      *m Stopper *n 2 to 5 mm (0.0787 to 0.197 in.)
      *o 0 to 1 mm (0 to 0.0394 in.) - -

  10. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. B006ES3

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

  11. INSTALL DISCHARGE HOSE SUB-ASSEMBLY


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

  12. 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 clamp.

      B006CXQC01
      *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.)

  13. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. B006CJY

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

  14. INSTALL RADIATOR RESERVE TANK HOSE


    1. Install the radiator reserve tank hose to the radiator assembly, and slide the clip to secure the hose.

      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)

      B006GQCC01
      *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.)

  15. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly together with the 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.

      B006F0JC01
      B006DHE Install in this Direction - -

  16. 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.

      B0069MQC01
      B006DHE Install in this Direction - -

  17. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


  18. CONNECT LIQUID TUBE SUB-ASSEMBLY A

    Click here

  19. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the upper radiator support sub-assembly with the 5 bolts.

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

  20. 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.

  21. INSTALL HOOD LOCK CONTROL CABLE COVER RH


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

    2. Install the screw.

  22. CONNECT ENGINE ROOM MAIN WIRE


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

    2. Connect the connector.

  23. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the water inlet with thermostat sub-assembly, and slide the clip to secure the hose.

      Note

      Install so that the No. 3 radiator hose paint mark and water inlet with thermostat sub-assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamps.

      B006FEKC01
      *1 No. 3 Radiator Hose - -
      *a View A *b 120°
      *c 29° *d Paint Mark
      *e Upper Side *f Rear 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.)

  24. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the water outlet sub-assembly, and slide the clip to secure the hose.

      Note

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

      B006B15C01
      *a View A *b 120°
      *c 48° *d Paint Mark
      *e Upper Side *f Rear 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.)

  25. CONNECT NO. 1 OIL COOLER INLET HOSE


    1. B006DDMC01
      *1 Radiator Pipe

      Connect the No. 1 oil cooler inlet hose to the radiator pipe, and slide the clip to secure the hose.

  26. 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.

  27. 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.

  28. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. B006H0F

      Install the radiator 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. B006GH5

      Connect the connector and attach the clamps.

    3. B006EFSC01
      *1 Radiator Pipe

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

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

      Note


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

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

      B006FGHC01
      *a View A *b 120°
      *c 45° *d Paint Mark
      *e Upper Side *f Rear 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.) - -

  29. INSTALL HIGH PITCHED HORN ASSEMBLY

    Click here

  30. INSTALL LOW PITCHED HORN ASSEMBLY

    Click here

  31. INSTALL HOOD LOCK ASSEMBLY

    Click here

  32. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  33. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH

    Click here

  34. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH

    Click here

  35. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

    Click here

  36. INSTALL NO. 1 AIR CLEANER INLET

    Click here

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

    Click here

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

    Click here

  39. INSTALL FRONT BUMPER


  40. ADD ENGINE COOLANT

    Click here

  41. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  42. INSPECT FOR COOLANT LEAK

    Click here

  43. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  44. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  45. INSTALL RADIATOR COVER PLATE

    Click here

  46. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  47. INSTALL OIL PAN PROTECTOR

    Click here

  48. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  49. INSPECT FOR COOLING FAN MOTOR

    Click here