RADIATOR INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


    1. A0137Q1

      Install the 2 radiator support cushions and 2 grommets to the radiator assembly.

    2. A01369K

      Install the fan assembly to the radiator assembly, with the claws and tighten the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
  2. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Install the front cross member sub-assembly with the 6 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
  3. CONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Install the radiator assembly with the 2 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
  4. CONNECT RADIATOR HOSE NO.2


    1. A0135SS

      Connect the radiator hose No.2 with a new clamp.

  5. CONNECT RADIATOR HOSE


    1. A0137E8

      Connect the radiator hose with a new clamp.

  6. CONNECT WATER BY-PASS HOSE


    1. A0136NJ

      Connect the water by-pass hose with a new hose clip.

  7. CONNECT RESISTOR CONNECTORS (w/ Air Conditioning System)


    1. A0137ZT

      Connect the 2 resistor connectors.

  8. CONNECT COOLING FAN MOTOR CONNECTOR


    1. A0137JZ

      Connect the cooling fan motor connector.

  9. ADD ENGINE COOLANT


    1. A01375N

      Install the drain plug with an O-ring and a new clip.

    2. Connect the radiator hose No.2.

    3. Pour engine coolant into the reserve tank assembly.

      Capacity
      4.0 to 4.4 L

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant may damage the engine coolant system.

      • Use only Premium Long Life Coolant for 1WZ and 2WZ-TV. Pre-mixed. Green. or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. A0136NJ

      Connect the water by-pass hose with the hose clamp.

      Tech Tips

      Connect the water by-pass hose, when the fluid flows clean and without air bubbles.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. Install the reservoir tank cap sub-assembly securely.

  10. START THE ENGINE

  11. CHECK FOR ENGINE COOLANT LEAKS


    1. Start the engine.

    2. Maintain the engine speed at 1,500 rpm until the first cooling cycle (cooling fan on).

    3. Stop the engine and wait for cool down.

    4. If necessary top up the level to the maximum mark.

  12. INSTALL SUPPORT LH SUB-ASSEMBLY

  13. INSTALL SUPPORT RH SUB-ASSEMBLY

  14. INSTALL FRONT BUMPER COVER

    A0136YZ

    1. Install the 2 clips.

    2. A01360O

      Engage the 13 claws and install the front bumper cover.

    3. A013716E01

      Tighten the 3 bolts and 5 screws.

    4. Install the 3 clips.

    5. Remove the protective tape.

  15. INSTALL ENGINE UNDER COVER


    1. A013649

      Install the engine under cover with the 5 screws.

    2. Install the 9 bolts.