RADIATOR REMOVAL

PROCEDURE


  1. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


  2. REMOVE OIL PAN PROTECTOR (for 2WD)

    Click here

  3. REMOVE FRONT SUSPENSION MEMBER BRACE (for AWD)

    Click here

  4. REMOVE STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for AWD)

    Click here

  5. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. REMOVE RADIATOR COVER PLATE

    Click here

  8. REMOVE LOWER RADIATOR AIR DEFLECTOR

    Click here

  9. REMOVE FRONT BUMPER


  10. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


  11. DRAIN ENGINE COOLANT

    Click here

  12. DRAIN COOLANT (for Inverter)

    Click here

  13. REMOVE RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH

    Click here

  14. REMOVE RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH

    Click here

  15. REMOVE NO. 1 AIR CLEANER INLET

    Click here

  16. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

    Click here

  17. REMOVE LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH

    Click here

  18. REMOVE LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH

    Click here

  19. REMOVE HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  20. REMOVE HOOD LOCK ASSEMBLY

    Click here

  21. REMOVE HIGH PITCHED HORN ASSEMBLY

    Click here

  22. REMOVE LOW PITCHED HORN ASSEMBLY

    Click here

  23. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. B004S7N

      Slide the clip and disconnect the radiator reserve tank hose from the radiator reserve tank assembly.

    2. B004V0SC01
      *1 Radiator Pipe

      Slide the clip and disconnect the reserve tank outlet hose from the radiator pipe.

    3. B004T6I

      Disconnect the connectors and detach the clamps.

    4. B004SQW

      Detach the clamp.

    5. B004VTA

      Remove the 2 bolts and radiator reserve tank assembly from the fan with motor assembly.

  24. REMOVE INVERTER RESERVE TANK ASSEMBLY


    1. for LHD:


      1. B004VBAC01
        *1 No. 6 Inverter Cooling Hose

        Detach the clamps.

      2. Slide the clip and disconnect the No. 6 inverter cooling hose from the inverter cooling pipe.

      3. B004S3GC01
        *1 No. 1 Inverter Cooling Hose

        Slide the clip and disconnect the No. 1 inverter cooling hose from the inverter water pump assembly (with motor).

        Note


        • Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the inverter water pump assembly and cooling system.

        • Do not apply excessive force to the No. 1 inverter cooling hose.

      4. B004T9O

        Remove the 2 bolts and inverter reserve tank assembly from the fan with motor assembly.

    2. for RHD:


      1. B004VW5C03
        *1 No. 5 Inverter Cooling Hose
        *2 No. 2 Inverter Cooling Hose Assembly
        *a Retainer
        B004RMI Lock Release Direction
        B004T3S Disconnection Direction

        Move the No. 5 inverter cooling hose retainer to release the lock and the disconnect the No. 2 inverter cooling hose assembly from the No. 5 inverter cooling hose.

      2. B004RQTC01
        *1 No. 1 Inverter Cooling Hose

        Slide the clip and disconnect the No. 1 inverter cooling hose from the inverter water pump assembly (with motor).

        Note


        • Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the inverter water pump assembly and cooling system.

        • Do not apply excessive force to the No. 1 inverter cooling hose.

      3. B004TUW

        Detach the clamps.

      4. Remove the 2 bolts and inverter reserve tank assembly from the fan with motor assembly.

  25. DISCONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. B004WXT

      Slide the clip and disconnect the No. 2 oil cooler outlet hose from the radiator assembly.

  26. DISCONNECT TRANSMISSION OIL COOLER HOSE


    1. B004X6V

      Detach the clamp.

    2. Slide the clip and disconnect the transmission oil cooler hose from the radiator assembly.

  27. DISCONNECT OIL COOLER INLET HOSE


    1. B004U6GC01
      *1 Radiator Pipe

      Slide the clip and disconnect the oil cooler inlet hose from the radiator pipe.

  28. DISCONNECT NO. 1 RADIATOR HOSE


    1. B004WI0

      Slide the clip and disconnect the No. 1 radiator hose from the water outlet sub-assembly.

  29. DISCONNECT NO. 3 RADIATOR HOSE


    1. B004W4OC01
      *1 No. 2 Radiator Hose
      *2 No. 3 Radiator Hose

      Detach the clamps from the No. 2 radiator hose and No. 3 radiator hose.

    2. Slide the clip and disconnect the No. 3 radiator hose from the water inlet with thermostat sub-assembly.

  30. DISCONNECT NO. 3 INVERTER COOLING HOSE


    1. for LHD:


      1. B004YSK

        Slide the clip and disconnect the No. 3 inverter cooling hose from the inverter cooling pipe.

    2. for RHD:


      1. B004VP7C02
        *1 No. 4 Inverter Cooling Hose
        *2 No. 3 Inverter Cooling Hose
        *a Retainer
        B004RMI Lock Release Direction
        B004T3S Disconnection Direction

        Move the No. 4 inverter cooling hose retainer to release the lock and the disconnect the No. 3 inverter cooling hose assembly from the No. 4 inverter cooling hose.

  31. DISCONNECT ENGINE ROOM MAIN WIRE


    1. B004Y9P

      Disconnect the connector.

    2. Detach the clamps and disconnect the engine room main wire.

  32. REMOVE HOOD LOCK CONTROL CABLE COVER LH (for LHD)


    1. B004TBL

      Remove the screw.

    2. Detach the clamp and disconnect the hood lock control cover LH.

  33. REMOVE HOOD LOCK CONTROL CABLE COVER RH


    1. B004SFA

      Remove the screw.

    2. Detach the clamp and disconnect the hood lock control cover RH.

  34. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. B004U1B

      Remove the 5 bolts and upper radiator support sub-assembly.

      Note

      Do not allow the cooler condenser assembly to interfere with the radiator assembly.

  35. DISCONNECT LIQUID TUBE SUB-ASSEMBLY A

    Click here

  36. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


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

      Click here

    • Compressor with Motor Assembly Side: (for AWD)

      Click here

    • Cooler Condenser Assembly Side:

      Click here

  37. REMOVE COOLER CONDENSER ASSEMBLY

    B004VAXC02
    *1 No. 2 Inverter Cooling Hose
    *2 No. 3 Inverter Cooling Hose

    1. Slide the clip and disconnect the No. 2 inverter cooling hose and No. 3 inverter cooling hose from the radiator assembly.

    2. Detach the claw.

    3. While lifting the cooler condenser assembly in the direction of the arrow shown in the illustration, detach the guide and remove the cooler condenser assembly.

      Note


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

      • Prepare a drain pan or cloth in case the coolant leaks.

      B004VVEC01
      B004RMI Remove in this Direction - -

  38. REMOVE RADIATOR ASSEMBLY


    1. for LHD:


      1. Remove the radiator assembly from the vehicle together with the fan with motor assembly as shown in the illustration.

        Note


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

        • When removing the radiator assembly from the vehicle, do not apply excessive force to the cooler pipe or cooling hoses.

        • Prepare a drain pan or cloth in case the coolant leaks.

        B004UTHC01
        B004RMI Remove in this Direction - -

    2. for RHD:


      1. Remove the radiator assembly from the vehicle together with the fan with motor assembly as shown in the illustration.

        Note


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

        • When removing the radiator assembly from the vehicle, do not apply excessive force to the cooler pipe or cooling hoses.

        • Prepare a drain pan or cloth in case the coolant leaks.

        B004RCGC01
        B004RMI Remove in this Direction - -

  39. REMOVE RADIATOR RESERVE TANK HOSE


    1. B004RWB

      Slide the clip and remove the radiator reserve tank hose from the radiator assembly.

  40. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. B004TB8

      Detach the claw and remove the rear radiator side air guide plate LH.

  41. REMOVE NO. 3 INVERTER COOLING HOSE


    1. for LHD:


      1. B004XL4C01
        B004SZX Clip
        B004UK4 Bolt

        Detach the clamps.

      2. Remove the clip, bolt and No. 3 inverter cooling hose from the radiator assembly.

    2. for RHD:


      1. B004WBHC01
        B004SZX Clip
        B004UK4 Bolt

        Remove the clip, bolt and No. 3 inverter cooling hose from the radiator assembly.

  42. REMOVE NO. 1 RADIATOR HOSE


    1. B004VAE

      Detach the clamp.

    2. Slide the clip and remove the No. 1 radiator hose from the radiator assembly.

  43. REMOVE DISCHARGE HOSE SUB-ASSEMBLY


    1. B004S7Y

      Detach the clamp and remove the discharge hose sub-assembly from the fan with motor assembly.

  44. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. B004UNP

      Detach the claw and remove the rear radiator side air guide plate RH.

  45. REMOVE NO. 2 RADIATOR HOSE


    1. B004U2CC02
      *1 No. 2 Radiator Hose
      *2 No. 3 Radiator Hose

      Detach the clamp.

    2. Slide the clip and remove the No. 2 radiator hose with No. 3 radiator hose from the radiator assembly.

  46. REMOVE NO. 2 INVERTER COOLING HOSE


    1. B004TC1C01
      B004SZX Hose Clip
      B004UK4 Clip

      Slide the hose clip and disconnect the No. 2 inverter cooling hose from the inverter water pump assembly (with motor).

      Note


      • Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the inverter water pump assembly and cooling system.

      • Do not apply excessive force to the No. 2 inverter cooling hose.

    2. Detach the clamp.

    3. Remove the 2 clips and No. 2 inverter cooling hose.

  47. REMOVE NO. 5 ENGINE ROOM WIRE


    1. B004YNZ

      Detach the clamps and disconnect the connector and remove the No. 5 engine room wire.

  48. REMOVE INVERTER WATER PUMP ASSEMBLY (WITH MOTOR)


    1. B004UB8

      Remove the 2 bolts and inverter water pump assembly (with motor).

  49. REMOVE FAN WITH MOTOR ASSEMBLY


    1. B004TJ4

      Remove the 2 bolts.

    2. Detach the 2 guides and remove the fan with motor assembly from the radiator assembly.

  50. REMOVE SUB-RADIATOR SUPPORT CUSHION


    1. B004Y56

      Remove the 2 sub-radiator support cushions from the radiator assembly.

  51. REMOVE LOWER RADIATOR SUPPORT


    1. B004SHD

      Remove the 2 lower radiator supports from the radiator assembly.

  52. REMOVE NO. 1 RADIATOR SUPPORT TO SEAL


    1. Upper Side:


      1. B004W3V

        Remove the No. 1 radiator to support seal from the radiator assembly.

    2. Lower Side:


      1. B004UEB

        Remove the No. 1 radiator to support seal from the radiator assembly.

  53. REMOVE NO. 2 RADIATOR SUPPORT TO SEAL


    1. B004TE2

      Remove the No. 2 radiator support to seal from the radiator assembly.

  54. REMOVE NO. 3 RADIATOR SUPPORT TO SEAL


    1. B004TEZ

      Remove the No. 3 radiator support to seal from the radiator assembly.

  55. REMOVE NO. 4 RADIATOR SUPPORT TO SEAL


    1. B004WXV

      Remove the No. 4 radiator support to seal from the radiator assembly.

  56. REMOVE NO. 5 RADIATOR SUPPORT TO SEAL


    1. B004S9A

      Remove the No. 5 radiator support to seal from the radiator assembly.