RADIATOR REMOVAL


  1. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A005RJS

      Remove the 9 clips and radiator support opening cover.

  2. 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.

  3. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A005U7U

      Remove the 4 screws and 2 bolts.

      Tech Tips

      Pull down the fender liner so that the front lower bumper absorber can be removed in the next step.

    2. A005TN1

      Remove the 3 screws, 8 bolts and front lower bumper absorber.

  4. REMOVE NO. 1 ENGINE UNDER COVER


    1. A005VAK

      Remove the 5 clips and under cover.

  5. REMOVE NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A005U17

      Remove the 3 bolts and under cover.

  6. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. 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.

  7. REMOVE BATTERY

  8. DRAIN ENGINE COOLANT

    Tech Tips

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

    CAUTION:

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


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap. Then drain the coolant from the radiator.

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

      A005R92E01
      Text in Illustration
      *1 Radiator Reservoir Cap *3 Cylinder Block Drain Cock Plug
      *2 Radiator Reservoir *4 Radiator Drain Cock Plug

    4. Tighten the radiator drain cock plug by hand.

    5. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  9. REMOVE NO. 1 RADIATOR HOSE


    1. A005VNT

      Disconnect the No. 1 radiator hose clamp.

    2. Disconnect the No. 1 radiator hose from the No. 2 water by-pass hose.

    3. Remove the No. 1 radiator hose.

  10. REMOVE NO. 2 RADIATOR HOSE


    1. A005SZ4

      Remove the No. 2 radiator hose.

  11. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A005VSY

      Disconnect the No. 3 water by-pass hose from the No. 2 water by-pass hose.

  12. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A005T0E

      Disconnect the 3 clamps and remove the No. 2 water by-pass hose.

  13. DISCONNECT NO. 1 WATER BY-PASS HOSE


    1. A005UWT

      Disconnect the No. 1 water by-pass hose.

  14. DISCONNECT OIL COOLER HOSE


    1. A005VY6

      Disconnect the 2 oil cooler hoses.

  15. DISCONNECT COOLING FAN MOTOR HARNESS


    1. A005UEB

      Disconnect the 2 fan motor connectors.

    2. Disconnect the variable resistor connector and 3 clamps.

  16. REMOVE NO. 1 WATER HOSE CLAMP BRACKET


    1. A005UN6

      Remove the 2 bolts and No. 1 water hose clamp bracket.

  17. REMOVE HOOD LOCK ASSEMBLY


    1. A005T6KE01

      Disconnect the 2 clamps.

    2. Remove the 3 bolts and disconnect the hood lock.

  18. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A005TDA

      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.

  19. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A005R66

      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.

  20. REMOVE AMBIENT TEMPERATURE SENSOR

    A005TU3

    1. Disconnect the connector.

    2. Using a screwdriver, detach the clamp and remove the sensor.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A005V6U

      Detach the claw and remove the cooler bracket.

  21. REMOVE UPPER RADIATOR SUPPORT


    1. A005VIA

      Disconnect the 2 horn connectors.

    2. Remove the 5 bolts and upper radiator support.

  22. REMOVE RADIATOR SUPPORT CUSHION


    1. A005USU

      Remove the 2 radiator support cushions.

  23. REMOVE RADIATOR ASSEMBLY


    1. A005SI9

      Remove the radiator with the 2 radiator support lower cushions.

      Tech Tips

      After detaching the radiator, make sure that both radiator support lower cushions are present.

  24. REMOVE NO. 2 FAN SHROUD


    1. A005VS2E01
      Text in Illustration
      *1 Protective Tape

      Disconnect the No. 3 water by-pass hose from the No. 2 fan shroud.

    2. Remove the 2 bolts

    3. Using a screwdriver, detach the 2 claws and remove the No. 2 fan shroud.

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A005R79

      Remove the No. 3 water by-pass hose.

  26. REMOVE OIL COOLER TUBE ASSEMBLY


    1. A005UL1

      Disconnect the oil cooler tube and detach the clamp.

    2. Remove the 2 bolts and oil cooler tube.

  27. REMOVE CONDENSER ASSEMBLY WITH RECEIVER


    1. Remove the condenser assembly with receiver.

    2. Remove the 4 cooler condenser cushions.

  28. REMOVE FAN SHROUD WITH COOLING FAN


    1. A005UYM

      Remove the 2 bolts and fan shroud from the radiator.

  29. REMOVE RADIATOR DRAIN COCK PLUG


    1. Remove the drain cock plug.

    2. Remove the O-ring.