RADIATOR (for AWD) REMOVAL

RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

SST

09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )
1. Start the engine.
2. Turn the A/C switch ON.
3. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.
4. Stop the engine.
5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.
REMOVE FRONT BUMPER REINFORCEMENT

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REMOVE V-BANK COVER SUB-ASSEMBLY
1. Using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B. Then slide the cover toward the front of the vehicle to detach the 2 clips labeled A and remove the V-bank cover sub-assembly.
  Note
  
  The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.
  
  When detaching the clips labeled A, be sure to slide the cover toward the front of the vehicle.
REMOVE NO. 1 AIR CLEANER INLET
1. Remove the 2 bolts.
2. Hold the No. 1 air cleaner inlet by the protrusions labeled A and labeled B, and detach the connections.
3. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled C.
4. Hold the No. 1 air cleaner inlet by the protrusions labeled D and labeled E, and detach the connections.
5. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled F.
REMOVE NO. 1 ENGINE UNDER COVER
1. Text in Illustration
  
  *A for 2WD
  
  *B for AWD
  
  Remove the 13 screws, 7 clips and No. 1 engine under cover.

Text in Illustration
*A	for 2WD
*B	for AWD

DRAIN ENGINE COOLANT

CAUTION:

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

Loosen the radiator drain cock plug.

Text in Illustration
*1	Radiator Drain Cock Plug	*2	Radiator Reservoir Cap
*3	Vent Plug	*4	Cylinder Block Drain Cock Plug

Tech Tips

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

Text in Illustration

*1 Vent Plug

Remove the radiator reservoir cap, and using a 6 mm hexagon wrench, remove the vent plug.
Drain coolant.
Loosen the 2 cylinder block drain cock plugs.

DRAIN AUTOMATIC TRANSMISSION FLUID
1. Remove the drain plug and gasket and drain the ATF.
2. Install a new gasket and the drain plug.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
REMOVE RADIATOR RESERVOIR ASSEMBLY
1. Disconnect the 2 reservoir hoses.
2. Remove the 2 bolts and radiator reservoir assembly.
REMOVE NO. 1 RADIATOR HOSE
1. Remove the No. 1 radiator hose.
REMOVE NO. 2 RADIATOR HOSE
1. Remove the No. 2 radiator hose.
DISCONNECT NO. 1 OIL COOLER INLET HOSE
1. Disconnect the No. 1 oil cooler inlet hose from the radiator.
  
  Note
  
  Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.
DISCONNECT NO. 1 OIL COOLER OUTLET HOSE
1. Disconnect the No. 1 oil cooler outlet hose from the radiator.
  
  Note
  
  Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.
REMOVE ENGINE ROOM ECU OUTLET DUCT
1. Remove the engine room ECU outlet duct from the fan shroud and ECU box.
REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)
1. Disconnect the connector.
2. Remove the 3 bolts.
3. Detach the 2 guides and remove the millimeter wave radar sensor assembly.
DISCONNECT HOOD LOCK CONTROL CABLE COVER
1. Remove the 3 screws and detach the claw to disconnect the hood lock control cable cover.
DISCONNECT HOOD LOCK ASSEMBLY
1. Remove the lock nut cap and lock nut.
2. Remove 2 bolts and disconnect the hood lock assembly.
3. Disconnect the connector.
REMOVE WIRE HARNESS
1. Disconnect the 3 connectors.
2. Detach the 8 wire harness clamps.
REMOVE RADIATOR UPPER SUPPORT SUB-ASSEMBLY
1. Disconnect the 3 connectors and detach the 5 wire harness clamps to disconnect the wire harness.
2. Remove the 5 bolts and radiator upper support.
REMOVE HOOD LOCK CONTROL CABLE COVER
1. Disconnect the wire harness clamp.
2. Disconnect the hood lock control cable and remove the hood lock control cable cover.
REMOVE HOOD LOCK ASSEMBLY
1. Remove the hood lock assembly from the hood lock control cable.
DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the bolt and disconnect the discharge hose sub-assembly from the cooler condenser assembly.
  Note
  
  When loosening the bolt, do not allow any tools to contact the hose.
  
  When loosening the bolt, hold a part of the hose near the connector.
2. Remove the O-ring from the discharge hose sub-assembly.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
DISCONNECT LIQUID TUBE SUB-ASSEMBLY A
1. Remove the 2 bolts and disconnect the liquid tube sub-assembly from the cooler condenser.
  Note
  
  When loosening the bolt, do not allow any tools to contact the tube.
  
  When loosening the bolt, hold a part of the tube near the connector.
2. Remove the O-ring from the liquid tube sub-assembly.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
REMOVE RADIATOR ASSEMBLY
1. Remove the radiator from the front crossmember together with the fan shroud with fan motor.
  
  Note
  
  Do not allow the radiator to interfere with other parts.
REMOVE FAN SHROUD WITH FAN AND MOTOR
1. Remove the 2 bolts.
2. Detach the claw, and then remove the fan shroud with fan and motor.
REMOVE COOLER CONDENSER ASSEMBLY
1. Remove the 4 bolts and cooler condenser assembly.
REMOVE RADIATOR SUPPORT CUSHION
1. Remove the 2 radiator support cushions.
REMOVE RADIATOR SUPPORT LOWER
1. Remove the 2 radiator support lowers.