RADIATOR INSTALLATION

PROCEDURE

1. INSTALL RADIATOR DRAIN COCK PLUG

   
   

   1. Install the O-ring to the radiator drain cock plug.

      Note

      Replace the O-ring if it is damaged.

   2. Install the radiator drain cock plug.

2. INSTALL RADIATOR ASSEMBLY

   
   

   1. Engage the 2 claws and install the radiator assembly to the fan shroud assembly.

      Note

      Do not damage the radiator assembly when installing the fan shroud assembly.

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

   3. Install the water by-pass hose to the radiator assembly and slide the clip to secure it.

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

   5. Engage the 2 clamps to connect the No. 1 radiator hose to the fan shroud assembly.

   6. Install the No. 2 water by-pass hose to the radiator assembly and slide the clip to secure it.

3. INSTALL INTERCOOLER COOLING RADIATOR ASSEMBLY

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4. INSTALL RADIATOR ASSEMBLY AND FAN SHROUD ASSEMBLY

   
   

   1. Install the 2 lower radiator supports.

   2. Install the radiator assembly and fan shroud assembly to the vehicle body.

   3. Engage the 4 wire harness clamps.

   4. Connect the cooling fan ECU connector.

5. INSTALL NO. 2 FAN SHROUD

   
   

   1. Engage the 3 claws.

   2. Install the No. 2 fan shroud to the radiator assembly with the 2 bolts.

      Torque:

      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

   3. Engage the 4 clamps to connect the No. 2 water by-pass hose to the No. 2 fan shroud.

6. 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. for RHD:

      
      

      1. Engage the clamp to connect the wire harness to the upper radiator support sub-assembly.

      2. Engage the 2 clamps to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

   3. for LHD:

      
      

      1. Engage the clamp to connect the wire harness to the upper radiator support sub-assembly. (w/ Engine Hood Courtesy Switch)

      2. Engage the 2 clamps to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

7. INSTALL UPPER RADIATOR SUPPORT

   
   

   1. Install the radiator support cushion to each upper radiator support.

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

      Torque:

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

8. CONNECT NO. 1 RADIATOR HOSE

   
   

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

9. CONNECT NO. 2 RADIATOR HOSE

   
   

   1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

10. CONNECT NO. 2 INTERCOOLER WATER HOSE

    
    

    1. Connect the No. 2 intercooler water hose to the intercooler reserve tank assembly and slide the clip to secure it.

11. CONNECT NO. 1 WATER BY-PASS HOSE

    
    

    1. Connect the No. 1 water by-pass hose to the intercooler reserve tank assembly and slide the clip to secure it.

    2. Engage the clamp to connect the No. 1 water by-pass hose to the No. 2 intercooler water hose.

12. CONNECT NO. 2 WATER BY-PASS HOSE

    
    

    1. Engage the clamp to connect the No. 2 water by-pass hose to the upper radiator support sub-assembly.

    2. Connect the No. 2 water by-pass hose to the intercooler reserve tank assembly and slide the clip to secure it.

13. INSTALL THERMISTOR ASSEMBLY

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14. INSTALL BATTERY TRAY

    
    

    1. Install the battery tray.

15. INSTALL BATTERY

    
    

    1. Install the battery.

    2. Install the battery insulator to the battery.

    3. Install the battery clamp sub-assembly with the battery clamp bolt, bolt and nut.

       Torque:

       Bolt

       16.5 N*m  { 168 kgf*cm, 12 ft.*lbf }

       Nut

       3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    4. Connect the cable to the positive (+) battery terminal and tighten the nut.

       Torque:

       5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

16. INSTALL ELECTRIC WATER PUMP ASSEMBLY

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17. CONNECT NO. 3 TURBO WATER HOSE

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18. CONNECT NO. 4 TURBO WATER HOSE

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

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20. CONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Air Conditioning System)

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

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

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23. INSTALL NO. 3 RADIATOR AIR GUIDE

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24. INSTALL HOOD LOCK ASSEMBLY

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25. INSTALL HEADLIGHT ASSEMBLY LH

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26. INSTALL HEADLIGHT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

28. ADD ENGINE COOLANT

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29. ADD ENGINE COOLANT (for Intercooler)

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30. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)

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31. INSPECT FOR COOLANT LEAK

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32. INSPECT FOR COOLANT LEAK (for Intercooler)

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

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

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