RADIATOR (w/ DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  3. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  5. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01DNWCE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  6. REMOVE FRONT BUMPER COVER

    Click here

  7. REMOVE FRONT BUMPER UPPER RETAINER


    1. A01DP8A

      Remove the 3 bolts and front bumper upper retainer.

  8. REMOVE RADIATOR SIDE DEFLECTOR RH


    1. A01DQIE

      Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector RH so that the radiator can be removed in the step below.

  9. REMOVE RADIATOR SIDE DEFLECTOR LH


    1. A01DNFT

      Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector LH so that the radiator can be removed in the step below.

  10. REMOVE NO. 1 AIR HOSE


    1. A01DTFB

      Loosen the 2 clamps.

    2. Remove the No. 1 air hose from the inlet pipe and intercooler.

  11. REMOVE INTERCOOLER AIR HOSE


    1. A01DT4O

      Disconnect the No. 2 vacuum transmitting hose from the intercooler.

    2. A01DM12

      Loosen the 2 clamps.

    3. Remove the intercooler air hose from the intake pipe and intercooler.

  12. REMOVE NO. 1 RADIATOR HOSE

    A01DT4C

  13. REMOVE NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)


    1. A01DO8C

      Remove the 2 nuts from the battery terminal.

    2. Detach the 3 wire harness clamps.

    3. Remove the No. 3 engine wire from the fan shroud.

  14. REMOVE FAN SHROUD


    1. A01DR1L

      Disconnect the No. 1 water by-pass hose and detach the 2 clamps from the fan shroud.

    2. Disconnect the No. 2 water by-pass hose from the radiator reservoir.

    3. Remove the 3 bolts and radiator reservoir.

    4. for Automatic Transmission:


      1. A01DPYW

        Remove the inlet and outlet oil cooler hoses and detach the clamp from the fan shroud.

      2. Disconnect the 2 oil cooler hoses from the radiator.

    5. A01DO7Q

      Loosen the 4 nuts holding the fan with fluid coupling.

    6. Remove the fan and generator V belt Click here.

    7. A01DPNM

      Remove the 2 bolts holding the fan shroud.

    8. Remove the 4 nuts for the fan with fluid coupling, and then remove the shroud together with the fan with fluid coupling.

      Note

      Be careful not to damage the radiator core.

    9. Detach the No. 2 water by-pass hose from the hose clamp on the fan shroud.

    10. A01DLWC

      Remove the No. 2 water by-pass hose from the water inlet.

    11. Remove the fan pulley from the water pump.

  15. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01DP14

      Slide the clamp and disconnect the No. 2 radiator hose from radiator assembly.

  16. REMOVE RADIATOR ASSEMBLY WITH INTERCOOLER ASSEMBLY


    1. A01DTP6

      Remove the 4 bolts and radiator assembly with intercooler assembly from the radiator support.

  17. REMOVE NO. 1 RADIATOR AIR GUIDE


    1. A01DR0W

      Remove the 2 bolts and No. 1 radiator air guide from the radiator assembly with intercooler assembly.

    2. A01DN9T

      Remove the No. 3 radiator to support seal from the No. 1 radiator air guide.

  18. REMOVE NO. 2 RADIATOR TO SUPPORT SEAL


    1. A01DMML

      Remove the 2 No. 2 radiator to support seals from the intercooler.

  19. REMOVE INTERCOOLER ASSEMBLY


    1. A01DP1T

      Disconnect the vacuum hose from the intercooler.

    2. Remove the 4 bolts and intercooler from the radiator.

  20. REMOVE OIL RETURN PIPE SUB-ASSEMBLY


    1. A01DPTI

      Detach the 2 clamps and remove the oil return pipe sub-assembly from the radiator assembly.

  21. REMOVE NO. 1 RADIATOR SUPPORT


    1. Remove the 2 No. 1 radiator supports from the radiator assembly.

  22. REMOVE NO. 2 RADIATOR SUPPORT


    1. Remove the 2 No. 2 radiator supports from the radiator assembly.

  23. REMOVE NO. 1 RADIATOR SUPPORT BUSH


    1. Remove the 4 No. 1 radiator support bushes from the radiator assembly.