PROCEDURE
INSTALL NO. 2 RADIATOR HOSE SUB-ASSEMBLY
Attach the clamp to install the No. 2 radiator hose sub-assembly to the fan shroud.
INSTALL FAN SHROUD
Install the fan shroud with the 3 bolts.
INSTALL INTERCOOLER ASSEMBLY
INSTALL NO. 2 RADIATOR SUPPORT
INSTALL COOLER CONDENSER ASSEMBLY
INSTALL UPPER RADIATOR SUPPORT
Install the 2 upper radiator supports with the 4 bolts.
INSTALL NO. 2 RADIATOR HOSE
Install the No. 2 radiator hose to the radiator assembly and slide the clamp to secure the hose.
INSTALL NO. 2 AIR TUBE
Install the No. 2 air tube to the intercooler assembly and No. 2 radiator support with the bolt.
Tighten the hose clamp to secure the No. 2 air tube.
INSTALL RADIATOR ASSEMBLY
Install the 2 cushions.
Install the radiator assembly together with the intercooler assembly to the vehicle.
Note
Do not allow the radiator assembly to interfere with other parts.
CONNECT NO. 2 RADIATOR HOSE
Note
Check that the retainer is closed when the connector is inserted.
If replacing the hose, apply fresh engine coolant to the O-ring.
Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.
Do not use a quick connector that has been dropped.
Push in the retainer and connect the No. 2 radiator hose to the water inlet.
INSTALL NO. 3 AIR HOSE
Connect the No. 3 air hose to the No. 2 air tube and tighten the hose clamp to secure the hose.
INSTALL NO. 2 AIR HOSE
Note
If replacing the intercooler air hose, check for deposits in the intercooler assembly and intercooler air hose. If necessary, wipe up deposits.
Connect the No. 2 air hose to the intercooler assembly and tighten the hose clamp to secure the hose.
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose to the radiator assembly and slide the hose clamp to secure the hose.
CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY
Connect the No. 2 radiator hose sub-assembly to the radiator assembly and slide the hose clamp to secure the hose.
CONNECT NO. 5 WATER BY-PASS HOSE
Attach the clamp to connect the No. 5 water by-pass hose to the fan shroud.
Connect the No. 5 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.
INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY
Install the upper radiator support sub-assembly with the 4 bolts.
INSTALL HOOD LOCK ASSEMBLY
for LHD
for RHD
CONNECT WIRE HARNESS
Connect the 3 connectors and attach the 10 wire harness clamps to connect the wire harness to the radiator assembly and fan shroud.
CONNECT WATER BY-PASS HOSE ASSEMBLY
Attach the hose clamp to connect the No. 5 water by-pass hose clamp to the hose clamp bracket.
Connect the water by-pass hose assembly to the upper radiator support sub-assembly with the bolt.
Connect the water by-pass hose to the reservoir assembly and slide the clamp to secure the hose.
INSTALL NO. 1 RADIATOR SUPPORT
Install the 2 radiator support cushions.
Install the 2 No. 1 radiator supports with the 2 bolts.
INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH
Install the rear radiator side air guide plate LH with the 2 clips.
INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH
Install the front radiator side air guide plate LH and attach the 3 claws.
INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH
Install the rear radiator side air guide plate RH with the 2 clips.
INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH
Install the front radiator side air guide plate RH and attach the 3 claws.
CONNECT LIQUID TUBE SUB-ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the liquid tube sub-assembly and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.
| Compressor Oil (for HFC-134a[R134a]) |
|---|
| Compressor oil ND-OIL 8 or equivalent |
| Compressor Oil (for HFO-1234yf[R1234yf]) |
|---|
| Compressor oil ND-OIL 12 or equivalent |
Connect the liquid tube sub-assembly to the cooler condenser assembly with the bolt.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the discharge hose sub-assembly and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
| Compressor Oil (for HFC-134a[R134a]) |
|---|
| Compressor oil ND-OIL 8 or equivalent |
| Compressor Oil (for HFO-1234yf[R1234yf]) |
|---|
| Compressor oil ND-OIL 12 or equivalent |
Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.
INSTALL FRONT BUMPER REINFORCEMENT
INSTALL LOWER RADIATOR AIR GUIDE PLATE
Install the lower radiator guide plate and attach the 3 claws.
INSTALL UPPER RADIATOR AIR GUIDE PLATE
Install the upper radiator air guide plate with 6 clips.
INSTALL FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY
Install the front bumper upper reinforcement sub-assembly with the 2 bolts and 2 clips.
Connect the connector to the horn.
INSTALL FRONT BUMPER CENTER STAY SUB-ASSEMBLY
Install the front bumper center stay sub-assembly with the 2 bolts.
Connect the connector to the horn.
INSTALL BATTERY BRACKET REINFORCEMENT
INSTALL BATTERY CARRIER ASSEMBLY
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
INSTALL FRONT LOWER BUMPER ABSORBER
Install the front lower bumper absorber with the 4 screws.
INSTALL HEADLIGHT ASSEMBLY
for Halogen Headlight
for LED Headlight
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
ADD ENGINE COOLANT
CHARGE REFRIGERANT (w/ Air Conditioning System)
for HFC-134a(R134a):
for HFO-1234yf(R1234yf):
WARM UP ENGINE (w/ Air Conditioning System)
for HFC-134a(R134a):
for HFO-1234yf(R1234yf):
INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
for HFC-134a(R134a):
for HFO-1234yf(R1234yf):
INSPECT FOR COOLANT LEAK
INSTALL NO. 1 ENGINE COVER
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 4 bolts, 2 screws and 10 clips.