RADIATOR INSTALLATION

PROCEDURE


  1. INSTALL FAN SHROUD


    1. A012JDQ

      Install the fan shroud to the radiator assembly with the 2 guides at the bottom and 2 bolts.

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

  2. INSTALL INTERCOOLER ASSEMBLY

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  3. INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY LH

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  4. INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY RH

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  5. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Connect the clamp and then install the No. 1 vacuum transmitting pipe sub-assembly.

    2. Connect the hose and slide the clip to secure it.

    3. Install the 3 bolts.

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

  6. INSTALL NO. 2 RADIATOR HOSE


    1. Install the No. 2 radiator hose and slide the clip to secure it.

  7. 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 No. 2 air tube and pipe of the intercooler.

      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 }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    3. Connect the intake air temperature sensor connector.

    4. Connect the clamp.

  8. INSTALL RADIATOR ASSEMBLY


    1. Install the 2 lower radiator supports.

    2. Install the radiator assembly with the fan shroud.

      Note

      For vehicles with the air conditioning system, do not apply excessive force to the condenser assembly or pipe when installing the radiator assembly.

    3. Connect the intake air temperature sensor connector, No. 2 cooling fan motor connector and cooling fan motor connector.

    4. Connect the clamp.

  9. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose and slide the clip to secure it.

  10. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose and clamp and slide the clip to secure it.

  11. INSTALL NO. 3 AIR HOSE

    Note

    Before installation, remove any oil residue from the inside of the diesel throttle body, No. 2 air tube and No. 3 air hose.


    1. A012IDXC01
      *a View A
      *b View B
      *c Matchmark
      *d 20°
      *e

      80°

      (Hose Clamp Area)
      *f 8°
      *g

      60°

      (Hose Clamp Area)

      Connect the No. 3 air hose to the No. 2 air tube and diesel throttle body as shown in the illustration.

    2. A012FT5N01

      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 }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tech Tips


      • Push in the No. 3 air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 2 to 7 mm (0.0787 to 0.276 in.).

    3. A012IFQN02

      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 }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tech Tips


      • Push in the No. 3 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.).

  12. INSTALL INTERCOOLER AIR HOSE

    Note


    • Check that the retainer is pushed in after installing the intercooler air hose.

    • If replacing the hose, check for deposits in the intercooler assembly and intercooler air hose. If necessary, clean deposits.

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

    • Do not use an intercooler air hose that has been dropped.


    1. A012MJSC01
      *a Retainer
      *b View A
      *c Matchmark
      *d

      90°

      (Hose Clamp Area)

      Connect the intercooler air hose to the intercooler assembly and push in the retainer, and connect the intercooler air hose to the No. 1 air tube as shown in the illustration.

    2. A012FT5N01

      Tighten the clamp of the intercooler air hose on the No. 1 air tube side.

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

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tech Tips


      • Push in the intercooler 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.).

  13. CONNECT NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Connect the No. 1 vacuum transmitting pipe sub-assembly and slide the clip to secure it.

  14. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the upper radiator support sub-assembly with the 4 bolts.

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

    2. Connect the wire harness with the 2 clamps.

    3. Connect the engine hood courtesy switch connector.

    4. Connect the hood lock control cable assembly to the upper radiator support sub-assembly with the 2 clamps.

    5. Connect the hood lock control cable assembly to the hood lock control lever sub-assembly.

  15. CONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. Connect the No. 1 water hose clamp bracket to the upper radiator support sub-assembly with the 2 bolts and 2 clamps.

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

  16. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose and slide the clip to secure it.

    2. Connect the clamp.

  17. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY LH


    1. Install the upper radiator support sub-assembly LH with the 2 bolts.

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

  18. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY RH


    1. Install the upper radiator support sub-assembly RH with the 2 bolts.

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

  19. INSTALL RADIATOR SUPPORT LH


    1. Install the radiator support cushion.

    2. Install the radiator support LH with the bolt.

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

  20. INSTALL RADIATOR SUPPORT RH


    1. Install the radiator support cushion.

    2. Install the radiator support RH with the bolt.

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

  21. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY


    1. A012MW5E01

      Install the radiator support to cross member brace sub-assembly with the 2 bolts.

      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the hone connector.

  22. INSTALL NO. 3 RADIATOR AIR GUIDE


    1. Engage the claw and install the No. 3 radiator air guide.

  23. INSTALL NO. 1 RADIATOR AIR GUIDE LH


    1. Engage the 2 claws and install the No. 1 radiator air guide LH with the clip.

  24. INSTALL NO. 1 RADIATOR AIR GUIDE RH


    1. Engage the 2 claws and install the No. 1 radiator air guide RH with the clip.

  25. INSTALL INJECTOR DRIVER

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  26. INSTALL BATTERY CARRIER BRACKET SUB-ASSEMBLY

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  27. INSTALL BATTERY

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  28. INSTALL THERMISTOR ASSEMBLY

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  29. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

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  30. INSTALL FRONT BUMPER ENERGY ABSORBER

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  31. INSTALL HEADLIGHT ASSEMBLY LH

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  32. INSTALL HEADLIGHT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  33. ADD ENGINE COOLANT

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  34. INSPECT FOR COOLANT LEAK

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  35. INSTALL NO. 1 ENGINE UNDER COVER