RADIATOR(for Manual Transaxle) INSTALLATION

PROCEDURE


  1. INSTALL FAN SHROUD


    1. A004O8K

      Insert the fan shroud hooks into the radiator holes and install the fan shroud with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  2. INSTALL INTERCOOLER ASSEMBLY

    Click here

  3. INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY

    Click here

  4. INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. Attach the clamp to the lower radiator support.

    2. Install the No. 3 vacuum transmitting pipe with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  5. INSTALL NO. 2 AIR TUBE


    1. Install the No. 2 air tube with the bolt.

      Note

      Before installation, remove any oil residue from the inside of the pipe and hose.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    2. Tighten the hose clamp.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    3. Connect the air temperature sensor connector.

  6. INSTALL RADIATOR ASSEMBLY


    1. Install the 2 radiator lower support cushions.

    2. Insert the radiator with intercooler while holding it at an angle to install it as shown in the illustration.

      Note

      w/ Air Conditioning System:

      Do not apply any excessive force to the cooler pipe when installing the radiator assembly.

    3. Connect the No. 2 vacuum transmitting hose.

  7. INSTALL CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)

    Click here

  8. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. Install the radiator support with the 4 bolts.

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

  9. INSTALL HOOD LOCK ASSEMBLY


    1. Install the hood lock with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Connect the hood lock control cable.

    3. w/ Engine Hood Courtesy Switch:

      Attach the clamp and connect the hood lock courtesy switch connector.

  10. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the 2 upper radiator supports with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the 2 radiator support cushions.

  11. INSTALL UPPER RADIATOR SUPPORT


    1. Install the 2 upper radiator supports with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  12. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  13. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  14. INSTALL NO. 3 AIR HOSE

    Note

    Before installation, remove any oil residue from the inside of the throttle body and tube.


    1. A004R0TE05
      Text in Illustration
      *1 Embossed Mark
      *2 Paint Mark
      *a Rear
      *b RH Side

      Align the paint mark of the No. 3 air hose with the embossed mark of the throttle body.

    2. Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.

    3. A004NAME03

      Tighten the clamp of the No. 3 air hose on the diesel throttle body side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

    4. A004T72E03

      Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

  15. INSTALL INTERCOOLER AIR HOSE

    Note


    • Check that the retainer is closed when the connector is inserted.

    • If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.

    • If replacing the hose, apply fresh oil to the O-ring.

    • Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.

    • Do not use a quick connector that has been dropped.


    1. A004TK5E01
      Text in Illustration
      *1 Retainer

      Install the intercooler air hose to the intercooler and No. 1 air tube and push in the retainer.

    2. Tighten the hose clamp.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  16. INSTALL NO. 2 RADIATOR HOSE


    1. A004QIUE03
      Text in Illustration
      *1 Match Mark
      *a View A
      *b View B
      *c Top
      *d LH Side
      *e RH Side

      Connect the No. 2 radiator hose.

      Tech Tips

      Position the clips as illustrated.

  17. INSTALL NO. 1 RADIATOR HOSE


    1. A004U5AE05
      Text in Illustration
      *1 Match Mark
      *a View A
      *b View B
      *c Top
      *d RH Side

      Connect the No. 1 radiator hose.

      Tech Tips

      Position clips A and B as Illustrated.

  18. INSTALL INJECTOR DRIVER

    Click here

  19. CONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. Connect the No. 1 water hose clamp bracket to the radiator support with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Attach the 2 hose clamps to the No. 2 by-pass water hose, and then connect the No. 1 radiator hose to the No. 1 water hose clamp bracket.

  20. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Connect the 3 connectors and attach the clamp.

    2. Install the No. 3 water by-pass hose and attach the clamp.

  21. INSTALL RADIATOR SIDE DEFLECTOR LH

  22. INSTALL RADIATOR SIDE DEFLECTOR RH

  23. INSTALL RADIATOR GRILLE BRACKET


    1. Install the radiator grille bracket with the 2 bolts and nut.

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

  24. INSTALL HORN ASSEMBLY


    1. Install the horn with the bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

    2. Connect the 2 horn connectors.

  25. CONNECT AMBIENT THERMISTOR ASSEMBLY


    1. Attach the clamp to connect the ambient thermistor.

  26. INSTALL BATTERY CARRIER

    Click here

  27. INSTALL BATTERY TRAY

  28. INSTALL BATTERY

  29. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  30. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  32. ADD ENGINE COOLANT

    Click here

  33. CHARGE REFRIGERANT (w/ Air Conditioning System)

    Click here

  34. WARM UP ENGINE (w/ Air Conditioning System)

    Click here

  35. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

    Click here

  36. INSPECT FOR COOLANT LEAK

    Click here

  37. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Install the radiator support opening cover with the 7 clips.

  38. INSTALL NO. 1 ENGINE COVER

    Click here

  39. INSTALL ENGINE UNDER COVER


    1. Install the engine under cover with the 11 clips.

  40. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Insert the 2 hooks of the front lower bumper absorber into the installation holes on the body to install the front lower bumper absorber.

    2. Install 8 bolts and 3 screws.

    3. Install the 4 screws and 2 bolts.