RADIATOR REMOVAL

PROCEDURE

1. REMOVE ENGINE ROOM SIDE COVER

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2. REMOVE COOL AIR INTAKE DUCT SEAL

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3. REMOVE INLET NO. 1 AIR CLEANER

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4. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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5. DRAIN ENGINE COOLANT

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6. REMOVE HOOD LOCK RELEASE LEVER PROTECTOR

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7. REMOVE HOOD LOCK ASSEMBLY

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8. REMOVE HOOD LOCK CONTROL CABLE COVER (for RHD)

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9. DISCONNECT HOOD LOCK CONTROL CABLE ASSEMBLY

   
   
   1. 

      *A	for RHD
      *B	for LHD

      Disengage the clamp to disconnect the hood lock control cable assembly from the upper radiator support.

10. REMOVE ENGINE ROOM ECU OUTLET DUCT

    

    
    

    1. Remove the engine room ECU outlet duct from the fan shroud assembly and engine room ECU box.

11. DISCONNECT ENGINE ROOM MAIN WIRE

    
    

    1. for Cooling Fan Motor 240 W + 240 W Type:

       
       

       1. 

          Disconnect the connector.

       2. Disconnect the cooling fan ECU connector.

       3. Disengage the clamp.

    2. for Cooling Fan Motor 300 W + 300 W Type:

       
       
       1. 

          *a	Lock Lever

          Disconnect the connector.

       2. Disengage the claw and raise the lock lever to disconnect the cooling fan motor connector as shown in the illustration.

       3. Disengage the clamp.

    3. 

       Disengage the 4 clamps to disconnect the engine room main wire from the upper radiator support.

12. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    
    
    1. 

       *1	Radiator Reserve Tank Hose
       *2	Reserve Tank Outlet Hose

       Slide the clip and disconnect the radiator reserve tank hose from the radiator assembly.

    2. Disengage the clamp to disconnect the radiator reserve tank hose from the fan shroud assembly.

    3. Slide the clip and disconnect the reserve tank outlet hose from the radiator reserve tank assembly.

    4. Disengage the 2 clamps to disconnect the reserve tank outlet hose from the fan shroud assembly.

    5. Disengage the 2 claws to remove the radiator reserve tank assembly from the fan shroud assembly.

13. REMOVE RADIATOR HOSE SUB-ASSEMBLY

    
    

    1. 

       Slide the 2 clips and remove the radiator hose sub-assembly from the radiator assembly and water inlet.

14. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    
    

    1. 

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

    2. Disconnect the No. 2 radiator hose sub-assembly from the radiator hose clamp.

    3. Remove the radiator hose clamp from the fan shroud assembly.

    4. Remove the bolt to disconnect the No. 2 radiator hose sub-assembly from the fan shroud assembly.

15. REMOVE UPPER RADIATOR SUPPORT

    
    

    1. 

       Disconnect the 2 horn connectors.

    2. Disconnect the smog ventilation sensor connector.

    3. 

       Disengage the 5 clamps to disconnect the wire harness from the upper radiator support.

    4. 

       Remove the 5 bolts and upper radiator support.

16. REMOVE FAN SHROUD ASSEMBLY

    
    
    1. 

       *A	for Cooling Fan Motor 240 W + 240 W Type
       *B	for Cooling Fan Motor 300 W + 300 W Type

       Disengage the 3 claws.

    2. Disengage the 3 guides to remove the fan shroud assembly from the radiator assembly.

       Note

       Make sure not to damage the radiator assembly when removing the fan shroud assembly.

17. REMOVE RADIATOR ASSEMBLY

    
    

    1. 

       Disengage the 2 claws.

    2. Disengage the 2 guides to separate the cooler condenser assembly and radiator assembly (for intercooler) from the radiator assembly.

       Note

       Make sure not to damage the cooler condenser assembly or radiator assembly (for intercooler) when removing the radiator assembly.

    3. Remove the radiator assembly from the vehicle body.

       Note

       Do not apply excessive force to the cooler condenser assembly, radiator assembly (for intercooler) or pipe when removing the radiator assembly.

18. REMOVE RADIATOR SUPPORT CUSHION

    
    

    1. Remove the 2 radiator support cushions from the radiator assembly.

19. REMOVE LOWER RADIATOR SUPPORT

    
    

    1. Remove the 2 lower radiator supports from the radiator assembly.