RADIATOR INSTALLATION

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. Install 2 new No. 1 radiator support to seals to the radiator assembly.

  6. INSTALL LOWER RADIATOR SUPPORT


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

  7. INSTALL RADIATOR SUPPORT CUSHION


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

  8. INSTALL FAN WITH MOTOR ASSEMBLY


    1. Attach the 2 guides.

    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. B000SH1C03
      *a View A
      *b 120°
      *c Paint Mark (White)
      *d Claw Center Direction
      *e Variation Range
      *f OK
      *g NG
      *h Upper Side
      *i LH Side

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

    2. Attach the clamp to install the No. 2 radiator hose to the fan with motor assembly.

  10. INSTALL NO. 2 INVERTER COOLING HOSE


    1. Install the No. 2 inverter cooling hose to the radiator assembly with the 2 clips and clamp.

  11. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. Attach the 2 claws to install the rear radiator side air guide plate RH to the radiator assembly.

  12. INSTALL DISCHARGE HOSE SUB-ASSEMBLY


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

  13. INSTALL NO. 1 RADIATOR HOSE


    1. B000P64C01
      *a View A
      *b 120°
      *c Paint Mark (White)
      *d Claw Center Direction
      *e Variation Range
      *f OK
      *g NG
      *h Upper Side
      *i LH Side

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

    2. Attach the clamp to install the No. 2 radiator hose to the fan with motor assembly.

  14. INSTALL NO. 3 INVERTER COOLING HOSE


    1. Install the No. 3 inverter cooling hose to the radiator assembly with the bolt and clip.

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

  15. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. Attach the 3 claws 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 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.

    2. B000R99C01
      B004C4F Bolt A
      B004ANI Bolt B

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      for bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Standard Length
      Item Length
      Bolt A 22.5 mm (0.886 in.)
      Bolt B 80 mm (3.15 in.)

    3. Attach the 2 guides.

    4. Attach the 2 claws and connect the cooler condenser assembly to the radiator assembly.

      Note

      Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

  17. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Connect the discharge hose sub-assembly to the cooler condenser assembly.

      Click here

    2. Connect the discharge hose sub-assembly to the cooler compressor assembly.

      Click here

  18. CONNECT LIQUID TUBE SUB-ASSEMBLY A

    Click here

  19. INSTALL HOOD LOCK SUPPORT BRACE


    1. Install the hood lock support brace to the front crossmember sub-assembly with the bolt.

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

  20. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the upper radiator support with the 5 bolts.

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

  21. CONNECT ENGINE ROOM MAIN WIRE


    1. Connect the 3 clamps, 4 connectors and engine room main wire.

  22. CONNECT OIL COOLER INLET HOSE


    1. B000SGTC01
      *a View A
      *b 120°
      *c Paint Mark
      *d 0 to 3 mm (0 to 0.118 in.)
      *e 2 to 7 mm (0.0787 to 0.2756 in.)
      *f Front Side
      *g Rear Side

      Connect the oil cooler inlet hose to the motor cooling cooler, and slide the clip to secure the hose.

      Note


      • Align the paint marks on the oil cooler inlet hose to the paint mark on the motor cooling cooler.

      • The hose clamp claw position is within the range shown in the illustration.

      • Do not deform the motor cooling cooler.

      • Water or coolant can be used to assist with inserting the hose, however when using liquid other than water, dilute it to 50% concentration or less before use.

  23. CONNECT TRANSMISSION OIL COOLER HOSE


    1. Connect the transmission oil cooler hose to the radiator assembly, and slide the clip to secure the hose.

  24. CONNECT NO. 3 ENGINE WIRE


    1. Connect the No. 3 engine wire with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Attach the 2 wire harness clamps and claw.

  25. CONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. Connect the No. 2 oil cooler outlet hose to the radiator assembly, and slide the clip to secure the hose.

  26. CONNECT NO. 3 INVERTER COOLING HOSE


    1. for LHD:

      Click here

    2. for RHD:


      1. Connect the No. 3 inverter cooling hose to the radiator assembly (for inverter coolant)

        Click here

      2. Connect the No. 3 inverter cooling hose to the No. 5 inverter cooling hose.

        Note

        Secure the quick connector retainer by locking it until a "click" sound is heard.

  27. CONNECT NO. 2 INVERTER COOLING HOSE

    Click here

  28. CONNECT NO. 2 INVERTER COOLING HOSE ASSEMBLY (for RHD)


    1. Connect the No. 2 inverter cooling hose assembly to the fan with motor assembly with the 3 clamps.

    2. Connect the No. 2 inverter cooling hose to the No. 4 inverter cooling hose.

      Note

      Secure the quick connector retainer by locking it until a "click" sound is heard.

  29. CONNECT NO. 6 INVERTER COOLING HOSE (for LHD)


    1. Connect the No. 6 inverter cooling hose to the inverter cooling inlet pipe assembly, and slide the clip to secure the hose.

  30. 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.

  31. CONNECT NO. 1 RADIATOR HOSE


    1. B000T2RC03
      *a View A
      *b 120°
      *c Paint Mark (Yellow)
      *d Claw Center Direction
      *e Rib
      *f OK
      *g NG
      *h Upper Side
      *i Rear Side

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

  32. INSTALL INVERTER WATER PUMP ASSEMBLY WITH MOTOR

    Click here

  33. INSTALL INVERTER RESERVE TANK ASSEMBLY

    Click here

  34. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. 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. for LHD:


      1. Attach the clamp to connect the No. 3 inverter cooling hose to the radiator reserve tank assembly.

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

      3. Install the radiator reserve tank hose, and slide the 2 clips to secure the hose.

    3. for RHD:


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

      2. Install the radiator reserve tank hose, and slide the 2 clips to secure the hose.

    4. Connect the 3 connectors, attach the 3 wire harness clamps to connect the engine room main wire from the radiator reserve tank assembly.

  35. INSTALL HOOD LOCK CONTROL CABLE COVER RH

    Click here

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

    Click here

  37. INSTALL HOOD LOCK ASSEMBLY

    Click here

  38. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  39. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH

    Click here

  40. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH

    Click here

  41. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Install the 4 screws, attach the 3 claws and install the radiator support opening cover to the front crossmember sub-assembly.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  42. INSTALL RADIATOR SUPPORT EXTENSION RH


    1. Install the 3 screws, attach the 2 claws and install the radiator support extension RH to the radiator support opening cover.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Connect the front fender liner RH to the radiator support extension RH with the 3 screws.

  43. INSTALL RADIATOR SUPPORT EXTENSION LH


    1. Install the 3 screws, attach the 2 claws and install the radiator support extension LH to the radiator support opening cover.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Connect the front fender liner LH to the radiator support extension LH with the 3 screws.

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


    1. Install the No. 2 front bumper reinforcement sub-assembly with the 6 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  45. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

    Click here

  46. INSTALL NO. 1 AIR CLEANER INLET

    Click here

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

    Click here

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

    Click here

  49. INSTALL FRONT BUMPER

    Click here

  50. ADD COOLANT (for Inverter)

    Click here

  51. ADD ENGINE COOLANT

    Click here

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  53. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  54. INSPECT FOR COOLANT LEAK

    Click here

  55. INSTALL ENGINE UNDER COVER REINFORCEMENT


    1. Install the engine under cover reinforcement to the strut bar bracket support sub-assembly with the 4 bolts.

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

  56. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  57. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  58. INSPECT FOR COOLING FAN MOTOR

    Click here