RADIATOR REMOVAL


  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  2. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      A003DK2E03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  3. REMOVE FRONT BUMPER REINFORCEMENT

    Click here

  4. REMOVE HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. A003DDAE01
      Text in Illustration
      *A for Standard Body
      *B for Wide Body

      Remove the 3 bolts and hood lock support brace sub-assembly.

  5. REMOVE W/RECEIVER CONDENSER ASSEMBLY

    Click here

  6. REMOVE NO. 1 AIR INLET DUCT


    1. A003ETF

      Detach the 5 clips and remove the 2 bolts, No. 1 air inlet duct and No. 2 air inlet duct.

  7. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. A003E3S

      Slide the clamp and disconnect the water by-pass hose from the radiator reserve tank assembly.

    2. Slide the clamp and disconnect the No. 2 water by-pass hose from the radiator reserve tank assembly.

    3. Remove the bolt and radiator reserve tank assembly.

  8. REMOVE WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY


    1. A003FBT

      Remove the 2 bolts and windshield washer motor and pump assembly.

    2. A003GHY

      Detach the hose clamp.

    3. Disconnect the 2 connectors and 2 washer hoses.

  9. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY


    1. A003H1Q

      Disconnect the 2 bolts and urea tank filler pipe assembly from the upper radiator support sub-assembly.

  10. REMOVE HOOD LOCK ASSEMBLY


    1. A003E6M

      Remove the 3 bolts and disconnect the hood lock assembly.

    2. Remove the hood lock assembly from the hood lock control cable assembly.

  11. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Slide the hose clamp and disconnect the water by-pass hose from the radiator assembly.

    2. A003AYK

      Detach the 2 clamps to disconnect the hood lock control cable assembly from the upper radiator support sub-assembly.

    3. Remove the 4 bolts, 2 screws and upper radiator support sub-assembly.

      Text in Illustration
      A003DCD Bolt
      A003GWQ Screw

  12. REMOVE INTERCOOLER ASSEMBLY


    1. A003ECE

      Loosen the hose clamp and disconnect the No. 2 air hose.

    2. Loosen the hose clamp and disconnect the No. 3 air hose.

    3. Remove the 3 bolts and intercooler.

  13. DISCONNECT OIL COOLER HOSE


    1. A003H16E01

      Detach the 2 clamps and disconnect the oil cooler hose from the fan shroud.

    2. Slide the 2 clamps and disconnect the 2 oil cooler hoses from the 2 oil cooler tubes.

  14. REMOVE FAN BRACKET SUB-ASSEMBLY


    1. A003B8U

      Detach the clamp and remove the 2 bolts, 2 nuts and fan bracket sub-assembly.

  15. REMOVE FAN SHROUD


    1. A003I8X

      Detach the 2 clamps and disconnect the 2 connectors.

    2. A003GKD

      Remove the 6 bolts and fan shroud from the underside of the vehicle.

  16. REMOVE NO. 2 FAN SHROUD


    1. Slide the hose clamp and disconnect the No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

    2. A003B2L

      Remove the bolt to disconnect the water by-pass pipe sub-assembly from the radiator assembly.

    3. A003HD7E02

      Remove the 2 bolts from the upper side of the vehicle, and then remove the No. 2 fan shroud from the underside of the vehicle.

      Note

      Do not damage the radiator assembly when removing the No. 2 fan shroud.

  17. REMOVE RADIATOR ASSEMBLY


    1. Slide the 2 clamps and disconnect the No. 2 radiator hose and No. 3 radiator hose from the radiator assembly.

    2. A003BA4

      Remove the radiator assembly from the vehicle.

    3. Remove the 4 grommets from the radiator assembly.

  18. REMOVE OIL COOLER HOSE


    1. A003C33

      Slide the 2 clamps and disconnect the 2 oil cooler hoses from the radiator assembly.

  19. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003H8R

      Slide the clamp and remove the water by-pass pipe sub-assembly from the radiator assembly.