INTERCOOLER REMOVAL


  1. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here

  2. 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.

  3. 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.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  5. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IRQL

      Remove the 6 bolts and 10 clips.

    2. Remove the No. 1 engine under cover.

  7. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01IOQE

      Remove the 2 clips.

    2. A01IPJ8

      Remove the 4 bolts.

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

  8. 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.

      A01IU4LE01
      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 - -

  9. REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      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.

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01IP71

      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 INSULATOR

  12. REMOVE BATTERY

  13. REMOVE BATTERY TRAY

  14. REMOVE BATTERY CARRIER


    1. A01ISD1

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  15. DISCONNECT AMBIENT TEMPERATURE SENSOR (w/ Air Conditioning System)

    A01IPBA

    1. Disconnect the connector.

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

      Tech Tips

      Tape the screwdriver tip before use.

  16. REMOVE LOW PITCHED HORN ASSEMBLY


    1. Disconnect the horn connector.

    2. Remove the bolt and low pitched horn assembly.

      A01IP2CE01

  17. REMOVE NO. 1 RADIATOR SIDE AIR SEAL


    1. A01IRKQ

      Remove the No. 1 radiator side air seal.

  18. REMOVE NO. 2 RADIATOR SIDE AIR SEAL


    1. A01ITUV

      Remove the No. 2 radiator side air seal.

  19. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A01IQOI

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

    2. A01IRP9

      Disconnect the 3 connectors and detach the clamp.

  20. DISCONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. A01IPG1

      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. A01IPA6

      Detach the clamp and disconnect the 4 injector driver connectors.

    2. A01IOBA

      Remove the 3 bolts and injector driver.

    3. A01IO2Q

      Remove the 4 screws and injector driver bracket.

  22. REMOVE NO. 1 RADIATOR HOSE


    1. A01IUM8

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

  23. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01IOKO

      Disconnect the No. 2 radiator hose.

  24. REMOVE INTERCOOLER AIR HOSE


    1. A01IRFKE01
      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. A01IMYT

      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)


    1. A01IUGE

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

    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 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning System)


    1. A01IQ6T

      Remove the bolt and disconnect the air conditioning tube and accessory assembly from the condenser.

    2. Remove the O-ring from the air conditioning tube and accessory 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. A01IT2T

      Remove the 2 bolts and 2 upper radiator supports.

  29. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Remove the 2 radiator support cushions.

    2. A01IN1Q

      Remove the 4 bolts and 2 upper radiator supports.

  30. REMOVE HOOD LOCK ASSEMBLY


    1. for LHD:


      1. A01IS1Z

        Remove the 3 bolts and hood lock.

      2. A01IO2N

        Disconnect the hood lock control cable.

    2. for RHD:


      1. A01ITHB

        Remove the 3 bolts and hood lock.

      2. Disconnect the connector.

      3. A01IQR4

        Disconnect the hood lock control cable.

  31. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A01IQCM

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

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


    1. A01IREB

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

  33. REMOVE RADIATOR ASSEMBLY


    1. A01IUHU

      Disconnect the No. 2 vacuum transmitting hose.

    2. A01INA2

      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. A01INTX

      Disconnect the air temperature sensor connector.

    2. Loosen the hose clamp.

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

  35. REMOVE LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01IQRAE01
      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. A01ISQYE01
      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.