RADIATOR INSTALLATION

PROCEDURE


  1. INSTALL FAN SHROUD


    1. Install the fan shroud with the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  2. INSTALL INTERCOOLER ASSEMBLY

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  3. INSTALL LOWER RADIATOR SUPPORT

    Click here

  4. INSTALL OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)


    1. B002A0UC01
      *a Top
      *b RH Side

      Connect the 2 hoses of the oil cooler hose tube sub-assembly to the radiator assembly and slide the 2 clips to secure the hose.

      Tech Tips

      Position the clips as illustrated.

    2. Install the oil cooler tube sub-assembly with the 2 bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  5. INSTALL NO. 2 RADIATOR HOSE


    1. Install the No. 2 radiator hose to the radiator assembly and slide the clamp to secure the hose.

      Tech Tips

      Position the clamp as illustrated.

      B002AE4C01
      *a Top

  6. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    B002AGTC01
    *a Top
    *b LH Side

    1. Install the radiator hose sub-assembly to the radiator assembly, and slide the 2 clamps to secure the hose.

      Tech Tips

      Position the clamps as illustrated.

    2. Attach the 2 clamps to the fan shroud.

  7. INSTALL NO. 2 AIR TUBE


    1. Install the No. 2 air tube to the intercooler assembly with the bolt.

      Note

      Before installation, remove any oil residue from the inside of the No. 2 air tube and intercooler assembly.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    2. B002A8CC01
      *a LH Side

      Tighten the hose clamp.

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

      Tech Tips

      Position the clamp as illustrated.

  8. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B0029USC01
      *a Top

      Attach the 4 clamps to the fan shroud and No. 2 air tube.

    2. Install the No. 2 vacuum transmitting hose assembly to the intercooler assembly and No. 2 air hose and 2 clips to secure the hose.

      Tech Tips

      Position the clips as illustrated.

  9. INSTALL COOLER CONDENSER ASSEMBLY


    1. Install the cooler condenser assembly.

  10. INSTALL NO. 2 RADIATOR SUPPORT


    1. Install the 2 No. 2 radiator supports with the 4 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  11. INSTALL RADIATOR ASSEMBLY


    1. Install the 2 cushions.

    2. Insert the radiator assembly.

    3. B002A9SC01
      *a Top
      *b Paint Mark
      *c Front Side of Vehicle

      for Automatic Transaxle


      1. Connect the 3 oil cooler hoses to the automatic transaxle, and slide the 3 clips to secure the hose.

        Tech Tips

        Position the clips as illustrated.

      2. Attach the clamp to the oil cooler tube sub-assembly.

  12. INSTALL NO. 3 AIR HOSE

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  13. INSTALL INTERCOOLER AIR HOSE

    Note

    Before installation, remove any oil residue from the inside of the intercooler air hose.


    1. B002AMJC01
      *A for Manual Transaxle
      *B for Automatic Transaxle
      *a Top
      *b LH Side

      Install the intercooler air hose to the No. 1 air tube and intercooler assembly and tighten the 2 hose clamps.

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

      Tech Tips

      Position the hose clamps as illustrated.

  14. CONNECT NO. 2 RADIATOR HOSE

    Click here

  15. CONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  16. INSTALL UPPER RADIATOR SUPPORT


    1. Install the upper radiator support with the 4 bolts.

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

  17. INSTALL HOOD LOCK ASSEMBLY



  18. CONNECT WIRE HARNESS


    1. Connect the 4 connectors to the fan motors, hood courtesy switch and intake air temperature sensor.

    2. Attach the 13 clamps to the fan shroud.

  19. CONNECT NO. 1 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose clamp bracket to the upper radiator support with the 2 bolts.

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

    2. Attach the hose clamp to the upper radiator support.

    3. Connect the No. 1 water by-pass hose to the radiator reservoir assembly, and radiator hose sub-assembly and slide the 2 clamps to secure the hose.

  20. INSTALL NO. 1 RADIATOR SUPPORT


    1. Install the 2 radiator support cushions.

    2. Install the 2 No. 1 radiator supports with the 2 bolts.

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

  21. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Connect the No. 2 vacuum transmitting hose assembly, and slide the clip secure the hose.

  22. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. Install the rear radiator side air guide plate LH with the 2 clips.

  23. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH


    1. Install the front radiator side air guide plate LH and attach the 3 claws.

  24. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. Install the rear radiator side air guide plate RH with the 2 clips.

  25. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH


    1. Install the front radiator side air guide plate RH and attach the 3 claws.

  26. CONNECT LIQUID TUBE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the liquid tube sub-assembly and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Connect the liquid tube sub-assembly to the cooler condenser assembly with the bolt.

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

  27. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the discharge hose sub-assembly and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

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

  28. INSTALL FRONT BUMPER REINFORCEMENT

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  29. CONNECT AMBIENT TEMPERATURE SENSOR ASSEMBLY


    1. Attach the clamp to connect the ambient thermistor assembly.

  30. INSTALL LOWER RADIATOR AIR GUIDE PLATE


    1. Install the lower radiator guide plate and attach the 3 claws.

  31. INSTALL UPPER RADIATOR AIR GUIDE PLATE


    1. Install the upper radiator air guide plate with 6 clips.

  32. INSTALL FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY


    1. Install the front bumper upper reinforcement sub-assembly with the 2 bolts.

      Tech Tips

      A bolt without a torque specification is shown in the standard bolt chart.

      Click here

  33. INSTALL FRONT BUMPER CENTER STAY SUB-ASSEMBLY


    1. Install the front bumper center stay sub-assembly with the 2 bolts and clip.

      Tech Tips

      A bolt without a torque specification is shown in the standard bolt chart.

      Click here

  34. INSTALL LOW PITCHED HORN ASSEMBLY

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  35. INSTALL HIGH PITCHED HORN ASSEMBLY

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  36. INSTALL BATTERY BRACKET REINFORCEMENT

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  37. INSTALL FRONT BATTERY BRACKET

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  38. INSTALL BATTERY TRAY

  39. INSTALL BATTERY

  40. INSTALL BATTERY INSULATOR

  41. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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  42. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Install the front lower bumper absorber with the 4 screws.

  43. INSTALL HEADLIGHT ASSEMBLY



  44. INSTALL FRONT BUMPER COVER

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  45. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  47. ADD ENGINE COOLANT

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  48. CHARGE REFRIGERANT

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  49. WARM UP ENGINE

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  50. INSPECT FOR REFRIGERANT LEAK

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  51. ADJUSTMENT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

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  52. INSPECT FOR COOLANT LEAK

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  53. INSTALL NO. 1 ENGINE COVER

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  54. INSTALL NO. 1 ENGINE UNDER COVER

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