RADIATOR REMOVAL


  1. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here

  2. REMOVE NO. 1 ENGINE COVER


    1. A01IRDDE01

      Lift the No. 1 engine cover to detach the 4 clips in the order shown in the illustration and remove the No. 1 engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  3. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IR30

      Remove the 6 bolts and 11 clips.

    2. Remove the No. 1 engine under cover.

  4. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01ISFZ

      Remove the 4 bolts.

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

  5. 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.

  6. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A01IUCQE01
      Text in Illustration
      *1 Reservoir Cap *2 Air Release Valve
      *3 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 reservoir cap.

  7. 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.

  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  9. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01ININ

      Remove the bolt and loosen the nut.

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

  11. REMOVE BATTERY INSULATOR

  12. REMOVE BATTERY

  13. REMOVE BATTERY TRAY

  14. REMOVE BATTERY CARRIER


    1. A01IQXM

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 4 bolts and battery carrier.

  15. DISCONNECT AMBIENT TEMPERATURE SENSOR

    A01IPBA

    1. Disconnect the connector.

    2. Using a screwdriver, detach the clamp and remove the sensor cooler thermistor (ambient temperature sensor).

      Tech Tips

      Tape the screwdriver tip before use.

  16. REMOVE LOW PITCHED HORN ASSEMBLY


    1. A01IOYG

      Remove the bolt.

    2. Disconnect the horn connector and remove the low pitched horn assembly.

  17. REMOVE NO. 1 RADIATOR SIDE AIR SEAL


    1. A01IRL6

      Detach the 2 clamps and remove the No. 1 radiator side air seal.

  18. REMOVE NO. 2 RADIATOR SIDE AIR SEAL


    1. A01INCG

      Detach the 2 clamps and remove the No. 2 radiator side air seal.

  19. DISCONNECT NO. 2 WATER BY-PASS HOSE


    1. A01IUBM

      Detach the 3 clamps to disconnect the No. 2 water by-pass hose from the 2 hose clamp brackets and No. 1 water hose clamp bracket.

  20. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01IQKY

      Detach the clamp to disconnect the No. 3 water by-pass hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 3 water by-pass hose from the radiator assembly.

  21. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01IN74

      Slide the hose clamp and disconnect the No. 1 radiator hose from the radiator assembly.

  22. DISCONNECT INTERCOOLER AIR HOSE


    1. A01INBL

      Loosen the hose clamp and disconnect the intercooler air hose from the intercooler assembly.

  23. DISCONNECT NO. 3 AIR HOSE


    1. A01IOI2

      Loosen the hose clamp and disconnect the No. 3 air hose from the intercooler assembly.

  24. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01INNVE01
      Text in Illustration
      *1 Retainer

      Pull out the retainer and disconnect the No. 2 radiator hose from the water inlet.

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


    1. A01IUGE

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

    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.

  26. 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 assembly with receiver.

    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.

  27. REMOVE UPPER RADIATOR SUPPORT


    1. A01IUBI

      Remove the 2 bolts and 2 upper radiator supports.

  28. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Remove the 2 cushions.

    2. A01IOKH

      Remove the 4 bolts and 2 upper radiator support sub-assemblies.

  29. 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.

  30. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. Detach the clamp to disconnect the hood lock control cable assembly from the hood lock support sub-assembly.

    2. A01IPQF

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

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


    1. A01IREB

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

  32. REMOVE RADIATOR ASSEMBLY


    1. A01IRVO

      Disconnect the 2 connectors and detach the clamp.

    2. A01IPWY

      Remove the radiator assembly from the vehicle together with the intercooler assembly.

      Note

      Do not allow the radiator assembly to interfere with other parts.

    3. Remove the 2 cushions.

  33. REMOVE NO. 2 RADIATOR HOSE


    1. A01IOIK

      Slide the hose clamp and remove the No. 2 radiator hose from the radiator assembly.

  34. REMOVE LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01ISBLE01
      Text in Illustration
      *1 Lower Radiator Support Sub-assembly LH
      *2 Lower Radiator Support Sub-assembly RH

      Remove the 2 bolts and lower radiator support sub-assembly LH.

    2. Remove the 2 bolts and lower radiator support sub-assembly RH.

  35. REMOVE INTERCOOLER ASSEMBLY


    1. A01IPS5

      Remove the 4 bolts and intercooler assembly.

  36. REMOVE FAN SHROUD


    1. A01ISI3

      Remove the 2 bolts and fan shroud.