RADIATOR REMOVAL

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

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  2. PRECAUTION

    Note

    After turning the ignition 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.

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  4. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  5. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01VAC3

      Remove the 4 bolts and 2 screws.

    2. Remove the 10 clips and No. 1 engine under cover.

  6. DRAIN ENGINE COOLANT

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  7. REMOVE HEADLIGHT ASSEMBLY



  8. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01V91H

      Remove the 4 screws and front lower bumper absorber.

  9. REMOVE NO. 1 ENGINE COVER

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  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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  11. REMOVE BATTERY INSULATOR

  12. REMOVE BATTERY

  13. REMOVE BATTERY TRAY

  14. REMOVE BATTERY CARRIER ASSEMBLY

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  15. REMOVE BATTERY BRACKET REINFORCEMENT

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  16. REMOVE FRONT BUMPER CENTER STAY SUB-ASSEMBLY


    1. A01V93N

      Disconnect the connector from the horn.

    2. Remove the 2 bolts and front bumper center stay sub-assembly.

  17. REMOVE FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY


    1. A01V916

      Disconnect the connector from the horn.

    2. Remove the 2 clips, 2 bolts and front bumper upper reinforcement sub-assembly.

  18. REMOVE UPPER RADIATOR AIR GUIDE PLATE


    1. A01V7A2

      Remove the 6 clips and upper radiator air guide plate.

  19. REMOVE LOWER RADIATOR AIR GUIDE PLATE


    1. A01V8IS

      Detach the 3 claws and remove the lower radiator air guide plate.

  20. REMOVE FRONT BUMPER REINFORCEMENT

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

    A01V9VE

    1. Remove the bolt and disconnect the discharge hose sub-assembly from the cooler condenser assembly.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  22. DISCONNECT LIQUID TUBE SUB-ASSEMBLY (w/ Air Conditioning System)

    A01V9S5

    1. Remove the bolt and disconnect the liquid tube sub-assembly from the cooler condenser assembly.

    2. Remove the O-ring from the liquid tube sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  23. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE RH


    1. A01V7VD

      Detach the 3 claws and remove the front radiator side air guide plate RH.

  24. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. A01VAC6

      Remove the 2 clips and rear radiator side air guide plate RH.

  25. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE LH


    1. A01V9PW

      Detach the 3 claws and remove the front radiator side air guide plate LH.

  26. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. A01V9EZ

      Remove the 2 clips and rear radiator side air guide plate LH.

  27. REMOVE NO. 1 RADIATOR SUPPORT


    1. Remove the 2 bolts and 2 No. 1 radiator supports.

      A01V96V

    2. Remove the 2 radiator support cushions.

  28. DISCONNECT WATER BY-PASS HOSE ASSEMBLY


    1. A01VB4N

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

    2. Detach the clamp to remove the No. 5 water by-pass hose from the hose clamp bracket

    3. Remove the bolt and disconnect the water by-pass hose assembly from the upper radiator support sub-assembly.

  29. DISCONNECT WIRE HARNESS


    1. A01VB16

      Disconnect the 3 connectors and detach the 10 wire harness clamps.

  30. REMOVE HOOD LOCK ASSEMBLY



  31. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01VAOY

      Remove the 4 bolts and upper radiator support sub-assembly.

  32. DISCONNECT NO. 5 WATER BY-PASS HOSE


    1. A01VAVS

      Detach the clamp to disconnect the No. 5 water by-pass hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 5 water by-pass hose from the radiator assembly.

  33. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY


    1. A01VA85

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

  34. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01V831

      Slide the hose clamp and disconnect the No. 1 radiator hose from the radiator assembly.

  35. REMOVE NO. 2 AIR HOSE


    1. A01V97T

      Loosen the hose clamp and disconnect the No. 2 air hose from the intercooler assembly.

  36. REMOVE NO. 3 AIR HOSE


    1. A01V9Y9

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

  37. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01V87EC02
      *a Retainer

      Pull out the retainer and disconnect the No. 2 radiator hose from the water inlet.

  38. REMOVE RADIATOR ASSEMBLY


    1. A01V8G8

      Remove the radiator assembly together with the intercooler assembly from the vehicle.

      Note

      Do not allow the radiator assembly to interfere with other parts.

    2. Remove the 2 cushions.

  39. REMOVE NO. 2 AIR TUBE


    1. A01V92A

      Loosen the hose clamp and remove the bolt and No. 2 air tube from the intercooler assembly.

  40. REMOVE NO. 2 RADIATOR HOSE


    1. A01VADM

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

  41. REMOVE UPPER RADIATOR SUPPORT


    1. Remove the 4 bolts and 2 upper radiator supports.

      A01VAF0

  42. REMOVE COOLER CONDENSER ASSEMBLY

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  43. REMOVE NO. 2 RADIATOR SUPPORT

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  44. REMOVE INTERCOOLER ASSEMBLY

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  45. REMOVE FAN SHROUD


    1. A01VAJ8

      Remove the 3 bolts and fan shroud.

  46. REMOVE NO. 2 RADIATOR HOSE SUB-ASSEMBLY


    1. Detach the clamp to remove the No. 2 radiator hose sub-assembly.