RADIATOR REMOVAL

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


  2. REMOVE OIL PAN PROTECTOR (for 2WD)

    Click here

  3. REMOVE FRONT SUSPENSION MEMBER BRACE (for AWD)

    Click here

  4. REMOVE STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for AWD)

    Click here

  5. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. REMOVE RADIATOR COVER PLATE

    Click here

  8. REMOVE LOWER RADIATOR AIR DEFLECTOR

    Click here

  9. REMOVE FRONT BUMPER


  10. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


  11. DRAIN ENGINE COOLANT

    Click here

  12. DRAIN COOLANT (for Intercooler)

    Click here

  13. REMOVE RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH

    Click here

  14. REMOVE RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH

    Click here

  15. REMOVE AIR CLEANER ASSEMBLY LH

    Click here

  16. REMOVE AIR CLEANER ASSEMBLY RH

    Click here

  17. REMOVE LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH

    Click here

  18. REMOVE LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH

    Click here

  19. REMOVE FRONT BUMPER ENERGY ABSORBER SUB-ASSEMBLY

    Click here

  20. REMOVE HEADLIGHT ASSEMBLY LH

    Click here

  21. REMOVE HEADLIGHT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  22. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here

  23. REMOVE FRONT BUMPER NO. 2 REINFORCEMENT SUB-ASSEMBLY

    Click here

  24. DISCONNECT NO. 3 ENGINE ROOM WIRE

    Click here

  25. REMOVE AIR CLEANER SUPPORT BRACKET

    Click here

  26. REMOVE HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  27. REMOVE HOOD LOCK ASSEMBLY

    Click here

  28. REMOVE HIGH PITCHED HORN ASSEMBLY

    Click here

  29. REMOVE LOW PITCHED HORN ASSEMBLY

    Click here

  30. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. B006A8K

      Slide the clip and disconnect the radiator reserve tank hose from the radiator assembly.

    2. B006ESM

      Disconnect the connectors and detach the clamps.

    3. B006ESWC01
      *1 Radiator Pipe

      Slide the clip and disconnect the reserve tank outlet hose from the radiator pipe.

    4. B006B7VC01
      B006AHR Bolt
      B006EC9 Clip

      Remove the 2 bolts, clip and radiator reserve tank assembly from the fan with motor assembly.

  31. REMOVE INTERCOOLER RESERVE TANK ASSEMBLY


    1. B006EUP

      Slide the clip and disconnect the intercooler reserve tank hose from the intercooler reserve tank assembly.

    2. for 2WD:


      1. B006CLLC01
        *1 Water By-pass Hose

        Slide the clip and disconnect the water by-pass hose from the electric water pump assembly.

        Note


        • Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the electric water pump assembly and cooling system.

        • Do not apply excessive force to the water by-pass hose.

    3. for AWD:


      1. B006EDRC01
        *1 Water By-pass Hose

        Slide the clip and disconnect the water by-pass hose from the electric water pump assembly.

        Note


        • Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the electric water pump assembly and cooling system.

        • Do not apply excessive force to the water by-pass hose.

    4. B006GFK

      Remove the 2 bolts and intercooler reserve tank assembly from the fan with motor assembly.

  32. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (w/ In-tank Oil Cooler)


    1. B006CGD

      Detach the clamp.

    2. Slide the clip and disconnect the No. 1 oil cooler outlet hose from the radiator assembly.

  33. DISCONNECT NO. 3 TRANSMISSION OIL COOLER HOSE (w/ In-tank Oil Cooler)


    1. B006FZB

      Detach the clamp.

    2. Slide the clip and disconnect the No. 3 transmission oil cooler hose from the radiator assembly.

  34. DISCONNECT NO. 3 RADIATOR HOSE


    1. B006F8Y

      Slide the clip and disconnect the No. 3 radiator hose from the water control valve.

  35. DISCONNECT NO. 4 RADIATOR HOSE


    1. B006D8B

      Detach the clamp.

    2. Slide the clip and disconnect the No. 4 radiator hose from the water inlet assembly.

  36. DISCONNECT WATER INLET HOSE


    1. B006CHT

      Detach the clamp.

    2. Slide the clip and disconnect the water inlet hose from the oil cooler assembly.

  37. DISCONNECT INTERCOOLER COOLING WATER OUTLET HOSE


    1. B006DHG

      Slide the clip and disconnect the intercooler cooling water outlet hose from the water tube.

  38. REMOVE HOOD LOCK SUPPORT BRACE


    1. Detach the clamps.

    2. Remove the 2 bolts and hood lock support brace.

      B006DXO

  39. DISCONNECT ENGINE ROOM MAIN WIRE


    1. B006G57

      Disconnect the connector.

    2. Detach the clamps and disconnect the engine room main wire.

  40. DISCONNECT HOOD LOCK CONTROL CABLE COVER LH (for LHD)


    1. B0069OE

      Remove the screw.

    2. Detach the clamp and disconnect the hood lock control cover LH.

  41. DISCONNECT HOOD LOCK CONTROL CABLE COVER RH


    1. B006BP8

      Remove the screw.

    2. Detach the clamp and disconnect the hood lock control cover RH.

  42. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. B006BZG

      Remove the 4 bolts and upper radiator support sub-assembly.

      Note

      Do not allow the cooler condenser assembly to interfere with the radiator assembly.

  43. DISCONNECT NO. 1 INTERCOOLER COOLING WATER HOSE


    1. B006CZO

      Slide the clip and disconnect the No. 1 intercooler cooling water hose from the intercooler water hose assembly.

  44. DISCONNECT NO. 2 INTERCOOLER COOLING WATER HOSE


    1. B006ERU

      Slide the clip and disconnect the No. 2 intercooler cooling water hose from the intercooler water hose assembly.

  45. DISCONNECT LIQUID TUBE SUB-ASSEMBLY A

    Click here

  46. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    • Compressor with Pulley Assembly Side: (for 2WD)

      Click here

    • Compressor with Pulley Assembly Side: (for AWD)

      Click here

    • Cooler Condenser Assembly Side:

      Click here

  47. REMOVE COOLER CONDENSER ASSEMBLY


    1. Detach the claw.

    2. While lifting the cooler condenser assembly in the direction of the arrow shown in the illustration, detach the guide and remove the cooler condenser assembly.

      Note


      • When removing the cooler condenser assembly, do not damage the cooler condenser assembly and radiator assembly.

      • Prepare a drain pan or cloth in case the coolant leaks.

      B006BQUC01
      B006DHE Remove in this Direction - -

  48. REMOVE NO. 1 RADIATOR AIR GUIDE LH


    1. B006FHV

      Remove the 5 clips and No. 1 radiator air guide LH.

  49. REMOVE NO. 1 RADIATOR AIR GUIDE RH


    1. B0069N9

      Remove the 5 clips and No. 1 radiator air guide RH.

  50. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly from the vehicle together with the intercooler cooling radiator assembly and fan with motor assembly as shown in the illustration.

      Note


      • Perform the following procedure with 2 or more people to prevent damage to the radiator assembly.

      • When removing the radiator assembly from the vehicle, do not apply excessive force to the cooler pipe or cooling hoses.

      • Prepare a drain pan or cloth in case the coolant leaks.

      B006FVDC01
      B006DHE Remove in this Direction - -

  51. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE LH


    1. B006FU5

      Detach the claw and remove the rear radiator side air guide plate LH.

  52. REMOVE DISCHARGE HOSE SUB-ASSEMBLY


    1. B006CUS

      Detach the clamp and remove the discharge hose sub-assembly from the fan with motor assembly.

  53. REMOVE INTERCOOLER COOLING WATER HOSE ASSEMBLY


    1. B006DG0

      Slide the clips and disconnect the intercooler water hose from the intercooler cooling radiator assembly.

    2. B006ET9

      Detach the clamp.

    3. Remove the 2 bolts and intercooler cooling water hose assembly.

  54. REMOVE INTERCOOLER COOLING RADIATOR ASSEMBLY

    Click here

  55. REMOVE NO. 1 RADIATOR HOSE


    1. B006A38C01
      *1 No. 1 Radiator Hose
      *2 No. 3 Radiator Hose

      Detach the clamps.

    2. Slide the clip and remove the No. 1 radiator hose with No. 3 radiator hose from the radiator assembly.

  56. REMOVE NO. 2 RADIATOR HOSE


    1. B006G5RC01
      *1 No. 2 Radiator Hose
      *2 No. 4 Radiator Hose
      *3 Water Inlet Hose

      Detach the clamp.

    2. Slide the clip and remove the No. 2 radiator hose with No. 4 radiator hose and water inlet hose from the radiator assembly.

  57. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE RH


    1. B006E08

      Detach the claw and remove the rear radiator side air guide plate RH.

  58. REMOVE NO. 1 RADIATOR TO SUPPORT SEAL


    1. Upper Side:


      1. B006D9C

        Remove the No. 1 radiator to support seal from the radiator assembly.

    2. Lower Side:


      1. B006GUA

        Remove the No. 1 radiator to support seal from the radiator assembly.

  59. REMOVE NO. 2 RADIATOR TO SUPPORT SEAL


    1. B006A02

      Remove the No. 2 radiator to support seal from the radiator assembly.

  60. REMOVE NO. 3 RADIATOR TO SUPPORT SEAL


    1. B0069MN

      Remove the No. 3 radiator to support seal from the radiator assembly.

  61. REMOVE NO. 4 RADIATOR TO SUPPORT SEAL


    1. B006DL5

      Remove the No. 4 radiator to support seal from the radiator assembly.

  62. REMOVE NO. 5 RADIATOR TO SUPPORT SEAL


    1. B006ANG

      Remove the No. 5 radiator to support seal from the radiator assembly.

  63. REMOVE FAN WITH MOTOR ASSEMBLY


    1. B006GJO

      Remove the 2 bolts.

    2. Detach the 2 guides and remove the fan with motor assembly from the radiator assembly.

      Note

      Do not disassemble the fan with motor assembly.

  64. REMOVE SUB-RADIATOR SUPPORT CUSHION


    1. B006B95

      Remove the 2 sub-radiator support cushions from the radiator assembly.

  65. REMOVE LOWER RADIATOR SUPPORT


    1. B006F81

      Remove the 2 lower radiator supports from the radiator assembly.