INTERCOOLER (for Automatic Transaxle) REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION 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 RADIATOR SUPPORT OPENING COVER


    1. A00OVQR

      Remove the 7 clips and radiator support opening cover.

  6. REMOVE FRONT BUMPER COVER


    1. A00OLT9E01

      Using a screwdriver, turn the pin hold clip 90° and remove the pin hold clip and screw.

      Tech Tips

      Use the same procedure for both pin hold clips and screws.

    2. A00OIPJ

      Remove the 9 screws.

    3. A00OHR9

      Remove the 2 clips and 3 bolts.

    4. A00OIJ8E01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front bumper cover.

    5. A00OMZK

      Detach the 10 claws and remove the front bumper cover.

    6. w/ Fog Light:

      Disconnect the 2 fog light connectors.

    7. w/ Headlight Cleaner System:

      Disconnect the headlight washer hose, and then drain the washer fluid.

      Tech Tips

      Use a container to collect the washer fluid.

  7. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A00OSJS

      Remove the 2 clips.

    2. A00OTHK

      Remove the 8 bolts.

    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.

  8. REMOVE ENGINE UNDER COVER


    1. A00ORDS

      Remove the 11 clips and engine under cover.

  9. 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.

      A010QK4E02
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -

  10. 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.

  11. 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.

  12. REMOVE BATTERY INSULATOR

  13. REMOVE BATTERY

  14. REMOVE BATTERY TRAY

  15. REMOVE BATTERY CARRIER


    1. A00OU72

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  16. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    A00OQPA

    1. Disconnect the sensor connector.

    2. Remove the 3 nuts and sensor.

  17. REMOVE NO. 1 MILLIMETER WAVE RADAR SENSOR BRACKET (w/ Dynamic Radar Cruise Control System)

    A00OT4A

    1. Remove the nut.

    2. Remove the 3 bolts and bracket.

  18. REMOVE OIL COOLER ASSEMBLY


    1. A00OULD

      Detach the 2 clips and disconnect the 2 oil cooler hoses from the oil cooler.

    2. Remove the 2 bolts, nut and oil cooler assembly.

  19. REMOVE RADIATOR GRILLE BRACKET


    1. A00OR7R

      Remove the bolt, nut and radiator grille bracket.

  20. REMOVE HORN ASSEMBLY


    1. A00OQTZ

      Disconnect the 2 horn connectors.

    2. Remove the bolt and horn.

  21. REMOVE AMBIENT THERMISTOR ASSEMBLY


    1. A00OSCL

      Detach the clamp and disconnect the ambient thermistor.

  22. REMOVE RADIATOR SIDE DEFLECTOR RH

    A00OTMC

  23. REMOVE RADIATOR SIDE DEFLECTOR LH

    A00OR2B

  24. REMOVE UPPER RADIATOR SUPPORT


    1. A00OQGS

      Remove the 2 bolts and 2 upper radiator supports.

  25. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Remove the 2 radiator support cushions.

    2. A00OSHN

      Remove the 4 bolts and 2 upper radiator supports.

  26. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    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

    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 CONDENSER ASSEMBLY WITH RECEIVER


    1. A00OQDK

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

  29. DISCONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. A00OU9T

      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.

  30. 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.

  31. REMOVE HOOD LOCK ASSEMBLY


    1. A00OV7Q

      w/ Engine Hood Courtesy Switch:

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

    2. Disconnect the hood lock control cable.

    3. 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.

  32. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A00OSUT

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

  33. REMOVE NO. 1 RADIATOR HOSE


    1. A00OSVG

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

  34. REMOVE NO. 2 RADIATOR HOSE

    A00OR3B

  35. REMOVE INTERCOOLER AIR HOSE


    1. A00OVYE

      Detach the clamp.

    2. Remove the bolt and wire harness bracket.

    3. A00OR24

      Loosen the hose clamps.

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

  36. REMOVE NO. 3 AIR HOSE


    1. A00OW1M

      Loosen the 2 clamps.

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

  37. REMOVE RADIATOR ASSEMBLY


    1. A00OUGV

      Disconnect the No. 2 vacuum transmitting hose.

    2. A00OU69

      Detach the 2 hose clips, and then disconnect the 2 oil cooler hoses.

    3. A00ORA8

      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

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

    4. Remove the 2 radiator lower support cushions.

  38. REMOVE NO. 2 AIR TUBE


    1. Disconnect the air temperature sensor connector.

    2. A00OUHZ

      Loosen the hose clamp.

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

  39. REMOVE LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A00OTK9E01
      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.

  40. REMOVE INTERCOOLER ASSEMBLY


    1. A00OTYVE01
      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.