INTERCOOLER REMOVAL


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


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  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 Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  5. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A00OVPY

      Remove the 4 screws and 2 bolts.

    2. A00OUR6

      Remove the 8 bolts and 3 screws.

    3. Detach the 2 hooks of the front lower bumper absorber from the installation holes on the body and remove the front lower bumper absorber.

  6. REMOVE ENGINE UNDER COVER


    1. A00ORDS

      Remove the 11 clips and engine under cover.

  7. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A00OSDBE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *5 Radiator Drain Cock Plug - -

  8. REMOVE NO. 1 ENGINE COVER


    1. A00ORGX

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  9. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A00OVQR

      Remove the 7 clips and radiator support opening cover.

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A00OQGF

      Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp from the battery carrier, and then remove the battery clamp.

  11. REMOVE BATTERY

  12. REMOVE BATTERY TRAY

  13. REMOVE BATTERY CARRIER


    1. A00OU72

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  14. DISCONNECT AMBIENT THERMISTOR ASSEMBLY (w/ Air Conditioning System)


    1. A00OSCL

      Detach the clamp and disconnect the ambient thermistor.

  15. REMOVE HORN ASSEMBLY


    1. A00OQTZ

      Disconnect the 2 horn connectors.

    2. Remove the bolt and horn.

  16. REMOVE RADIATOR GRILLE BRACKET


    1. A00OT1Y

      Remove the 2 bolts, nut and the radiator grille bracket.

  17. REMOVE RADIATOR SIDE DEFLECTOR RH

    A00OQU4

  18. REMOVE RADIATOR SIDE DEFLECTOR LH

    A00ORQL

  19. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A00OR47

      Detach the clamp and remove the No. 3 water by-pass hose.

    2. A00OSTD

      Disconnect the 3 connectors and detach the clamp.

  20. DISCONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. A00OQTC

      Disconnect the No. 1 radiator hose from the No. 1 water hose clamp bracket.

    2. Detach the 2 hose clamps from the No. 2 by-pass water hose.

    3. Remove the 2 bolts and disconnect the No. 1 water hose clamp bracket from the radiator support.

  21. REMOVE INJECTOR DRIVER


    1. A00ORHG

      Detach the clamp and disconnect the 4 injector driver connectors.

    2. A00OV7Z

      Remove the 3 bolts and injector driver.

    3. A00OT2I

      Remove the 4 screws and injector driver bracket.

  22. REMOVE NO. 1 RADIATOR HOSE


    1. A00OSVG

      Detach the hose clamp and remove the No. 1 radiator hose.

  23. REMOVE NO. 2 RADIATOR HOSE

    A00OT9C

  24. REMOVE INTERCOOLER AIR HOSE


    1. A00OV1QE03
      Text in Illustration
      *1 Retainer

      Disconnect the intercooler air hose from the No. 1 air tube.

    2. Pull out the retainer and remove the intercooler air hose from the intercooler.

  25. REMOVE NO. 3 AIR HOSE


    1. A00OVB7

      Loosen the 2 clamps.

    2. Remove the No. 3 air hose from the No. 2 air tube and throttle body.

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

    A00OTA9

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

      Note

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

    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.

  27. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Air Conditioning System)

    A00OQW8

    1. Remove the bolt and disconnect the suction pipe sub-assembly from the condenser.

      Note

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

    2. Remove the O-ring from the suction pipe sub-assembly.

      Note

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

  28. REMOVE UPPER RADIATOR SUPPORT


    1. A00OQGS

      Remove the 2 bolts and 2 upper radiator supports.

  29. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Remove the 2 radiator support cushions.

    2. A00OSHN

      Remove the 4 bolts and 2 upper radiator supports.

  30. REMOVE HOOD LOCK ASSEMBLY


    1. A00OUGR

      w/ Engine Hood Courtesy Switch:

      Disconnect the hood lock courtesy switch connector and detach the clamp.

    2. Detach the wire harness clamp.

    3. Disconnect the hood lock control cable.

    4. A00OR7EE03
      Text in Illustration
      *A w/o Engine Hood Courtesy Switch
      *B w/ Engine Hood Courtesy Switch
      *1 Engine Hood Courtesy Switch

      Remove the 3 bolts and hood lock.

  31. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A00OU8P

      Remove the 4 bolts and hood lock support sub-assembly.

  32. REMOVE CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)


    1. A00OQDK

      Remove the condenser assembly with receiver as shown in the illustration.

  33. REMOVE RADIATOR ASSEMBLY


    1. A00OUGV

      Disconnect the No. 2 vacuum transmitting hose.

    2. A00OUEJ

      Push the side of the radiator with intercooler towards the transaxle as shown in the illustration, and lift the radiator with intercooler upward out of the vehicle to remove it.

      Note

      w/ Air Conditioning System:

      Do not apply any excessive force to the cooler condenser pipe when removing the radiator assembly.

    3. Remove the 2 radiator lower support cushions.

  34. REMOVE NO. 2 AIR TUBE


    1. Disconnect the air temperature sensor connector.

    2. A00OR11

      Loosen the hose clamp.

    3. Remove the bolt and No. 2 air tube.

  35. REMOVE LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A00OU2QE01
      Text in Illustration
      *1 Lower Radiator Support LH
      *2 Lower Radiator Support RH

      Remove the 2 bolts, detach the clamp from the vacuum transmitting pipe, and then remove the lower radiator support LH.

    2. Remove the 2 bolts and lower radiator support RH.

  36. REMOVE INTERCOOLER ASSEMBLY


    1. A00OVN5E01
      Text in Illustration
      *1 No. 1 Vacuum Transmitting Hose

      Disconnect the No. 1 vacuum transmitting hose from the intercooler.

    2. Remove the 4 bolts and intercooler.