RADIATOR INSTALLATION
PROCEDURE
INSTALL NO. 2 RADIATOR HOSE SUB-ASSEMBLY
Attach the clamp to install the No. 2 radiator hose sub-assembly to the fan shroud.
INSTALL FAN SHROUD
Install the fan shroud with the 3 bolts.
5.5 N*m
56 kgf*cm
49 in.*lbf
INSTALL INTERCOOLER ASSEMBLY
INSTALL NO. 2 RADIATOR SUPPORT
INSTALL COOLER CONDENSER ASSEMBLY
INSTALL UPPER RADIATOR SUPPORT
Install the 2 upper radiator supports with the 4 bolts.
5.5 N*m
56 kgf*cm
49 in.*lbf
INSTALL NO. 2 RADIATOR HOSE
Install the No. 2 radiator hose to the radiator assembly and slide the clamp to secure the hose.
INSTALL NO. 2 AIR TUBE
Install the No. 2 air tube to the intercooler assembly and No. 2 radiator support with the bolt.
31 N*m
316 kgf*cm
23 ft.*lbf
Tighten the hose clamp to secure the No. 2 air tube.
6.5 N*m
66 kgf*cm
58 in.*lbf
INSTALL RADIATOR ASSEMBLY
Install the 2 cushions.
Install the radiator assembly together with the intercooler assembly to the vehicle.
Note:Do not allow the radiator assembly to interfere with other parts.
CONNECT NO. 2 RADIATOR HOSE
Note:Check that the retainer is closed when the connector is inserted.
If replacing the hose, apply fresh engine coolant to the O-ring.
Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.
Do not use a quick connector that has been dropped.
Push in the retainer and connect the No. 2 radiator hose to the water inlet.
INSTALL NO. 3 AIR HOSE
Connect the No. 3 air hose to the No. 2 air tube and tighten the hose clamp to secure the hose.
6.5 N*m
66 kgf*cm
58 in.*lbf
INSTALL NO. 2 AIR HOSE
Note:If replacing the intercooler air hose, check for deposits in the intercooler assembly and intercooler air hose. If necessary, wipe up deposits.
Connect the No. 2 air hose to the intercooler assembly and tighten the hose clamp to secure the hose.
6.5 N*m
66 kgf*cm
58 in.*lbf
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose to the radiator assembly and slide the hose clamp to secure the hose.
CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY
Connect the No. 2 radiator hose sub-assembly to the radiator assembly and slide the hose clamp to secure the hose.
CONNECT NO. 5 WATER BY-PASS HOSE
Attach the clamp to connect the No. 5 water by-pass hose to the fan shroud.
Connect the No. 5 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.
INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY
Install the upper radiator support sub-assembly with the 4 bolts.
31 N*m
316 kgf*cm
23 ft.*lbf
INSTALL HOOD LOCK ASSEMBLY
for LHD
for RHD
CONNECT WIRE HARNESS
Connect the 3 connectors and attach the 10 wire harness clamps to connect the wire harness to the radiator assembly and fan shroud.
CONNECT WATER BY-PASS HOSE ASSEMBLY
Attach the hose clamp to connect the No. 5 water by-pass hose clamp to the hose clamp bracket.
Connect the water by-pass hose assembly to the upper radiator support sub-assembly with the bolt.
5.0 N*m
51 kgf*cm
44 in.*lbf
Connect the water by-pass hose to the reservoir assembly and slide the clamp to secure the hose.
INSTALL NO. 1 RADIATOR SUPPORT
Install the 2 radiator support cushions.
Install the 2 No. 1 radiator supports with the 2 bolts.
19 N*m
194 kgf*cm
14 ft.*lbf
INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH
Install the rear radiator side air guide plate LH with the 2 clips.
INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH
Install the front radiator side air guide plate LH and attach the 3 claws.
INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH
Install the rear radiator side air guide plate RH with the 2 clips.
INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH
Install the front radiator side air guide plate RH and attach the 3 claws.
CONNECT LIQUID TUBE SUB-ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the liquid tube sub-assembly and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.
Compressor Oil
ND-OIL 8 or equivalent
Connect the liquid tube sub-assembly to the cooler condenser assembly with the bolt.
5.4 N*m
55 kgf*cm
48 in.*lbf
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the discharge hose sub-assembly and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
Compressor Oil
ND-OIL 8 or equivalent
Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.
5.4 N*m
55 kgf*cm
48 in.*lbf
INSTALL FRONT BUMPER REINFORCEMENT
INSTALL LOWER RADIATOR AIR GUIDE PLATE
Install the lower radiator guide plate and attach the 3 claws.
INSTALL UPPER RADIATOR AIR GUIDE PLATE
Install the upper radiator air guide plate with 6 clips.
INSTALL FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY
Install the front bumper upper reinforcement sub-assembly with the 2 bolts and 2 clips.
Connect the connector to the horn.
INSTALL FRONT BUMPER CENTER STAY SUB-ASSEMBLY
Install the front bumper center stay sub-assembly with the 2 bolts.
Connect the connector to the horn.
INSTALL BATTERY BRACKET REINFORCEMENT
INSTALL BATTERY CARRIER ASSEMBLY
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
INSTALL FRONT LOWER BUMPER ABSORBER
Install the front lower bumper absorber with the 4 screws.
INSTALL HEADLIGHT ASSEMBLY
for Halogen Headlight
for LED Headlight
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
ADD ENGINE COOLANT
CHARGE REFRIGERANT (w/ Air Conditioning System)
WARM UP ENGINE (w/ Air Conditioning System)
INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
INSPECT FOR COOLANT LEAK
INSTALL NO. 1 ENGINE COVER
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 4 bolts, 2 screws and 10 clips.