RADIATOR INSTALLATION

PROCEDURE

  1. INSTALL FAN SHROUD

    1. Install the fan shroud with the 3 bolts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  2. INSTALL INTERCOOLER ASSEMBLY

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  3. INSTALL LOWER RADIATOR SUPPORT

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  4. INSTALL OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)

    1. A295986C01

      *a

      Top

      *b

      RH Side

      Connect the 2 hoses of the oil cooler hose tube sub-assembly to the radiator assembly and slide the 2 clips to secure the hose.

      Tip:

      Position the clips as illustrated.

    2. Install the oil cooler tube sub-assembly with the 2 bolt.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  5. INSTALL NO. 2 RADIATOR HOSE

    1. Install the No. 2 radiator hose to the radiator assembly and slide the clamp to secure the hose.

      A295982C01

      *a

      Top
      Tip:

      Position the clamp as illustrated.

  6. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    A297505C01

    *a

    Top

    *b

    LH Side

    1. Install the radiator hose sub-assembly to the radiator assembly, and slide the 2 clamps to secure the hose.

      Tip:

      Position the clamps as illustrated.

    2. Attach the 2 clamps to the fan shroud.

  7. INSTALL NO. 2 AIR TUBE

    1. Install the No. 2 air tube to the intercooler assembly with the bolt.

      Note:

      Before installation, remove any oil residue from the inside of the No. 2 air tube and intercooler assembly.

      31 N*m

      316 kgf*cm

      23 ft.*lbf

    2. A295984C01

      *a

      LH Side

      Tighten the hose clamp.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Tip:

      Position the clamp as illustrated.

  8. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A295983C01

      *a

      Top

      Attach the 4 clamps to the fan shroud and No. 2 air tube.

    2. Install the No. 2 vacuum transmitting hose assembly to the intercooler assembly and No. 2 air hose and 2 clips to secure the hose.

      Tip:

      Position the clips as illustrated.

  9. INSTALL COOLER CONDENSER ASSEMBLY

    1. Install the cooler condenser assembly.

  10. INSTALL NO. 2 RADIATOR SUPPORT

    1. Install the 2 No. 2 radiator supports with the 4 bolts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  11. INSTALL RADIATOR ASSEMBLY

    1. Install the 2 cushions.

    2. Insert the radiator assembly.

    3. A297516C01

      *a

      Top

      *b

      Paint Mark

      *c

      Front Side of Vehicle

      for Automatic Transaxle

      1. Connect the 3 oil cooler hoses to the automatic transaxle, and slide the 3 clips to secure the hose.

        Tip:

        Position the clips as illustrated.

      2. Attach the clamp to the oil cooler tube sub-assembly.

  12. INSTALL NO. 3 AIR HOSE

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  13. INSTALL INTERCOOLER AIR HOSE

    Note:

    Before installation, remove any oil residue from the inside of the intercooler air hose.

    1. A297531C01

      *A

      for Manual Transaxle

      *B

      for Automatic Transaxle

      *a

      Top

      *b

      LH Side

      Install the intercooler air hose to the No. 1 air tube and intercooler assembly and tighten the 2 hose clamps.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Tip:

      Position the hose clamps as illustrated.

  14. CONNECT NO. 2 RADIATOR HOSE

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  15. CONNECT RADIATOR HOSE SUB-ASSEMBLY

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  16. INSTALL UPPER RADIATOR SUPPORT

    1. Install the upper radiator support with the 4 bolts.

      31 N*m

      316 kgf*cm

      23 ft.*lbf

  17. INSTALL HOOD LOCK ASSEMBLY

  18. CONNECT WIRE HARNESS

    1. w/ Towing Package:

      1. Connect the 3 connectors to the cooling fan ECU and intake air temperature sensor.

      2. Attach the 11 clamps to the fan shroud.

    2. w/o Towing Package:

      1. Connect the 4 connectors to the fan motors, hood courtesy switch and intake air temperature sensor.

      2. Attach the 13 clamps to the fan shroud.

  19. CONNECT NO. 1 WATER BY-PASS HOSE

    1. Connect the No. 1 water by-pass hose clamp bracket to the upper radiator support with the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. Attach the hose clamp to the upper radiator support.

    3. Connect the No. 1 water by-pass hose to the radiator reservoir assembly, and radiator hose sub-assembly and slide the 2 clamps to secure the hose.

  20. INSTALL NO. 1 RADIATOR SUPPORT

    1. Install the 2 radiator support cushions.

    2. Install the 2 No. 1 radiator supports with the 2 bolts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

  21. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. Connect the No. 2 vacuum transmitting hose assembly, and slide the clip secure the hose.

  22. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH

    1. Install the rear radiator side air guide plate LH with the 2 clips.

  23. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH

    1. Install the front radiator side air guide plate LH and attach the 3 claws.

  24. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH

    1. Install the rear radiator side air guide plate RH with the 2 clips.

  25. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH

    1. Install the front radiator side air guide plate RH and attach the 3 claws.

  26. CONNECT LIQUID TUBE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the liquid tube sub-assembly and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Connect the liquid tube sub-assembly to the cooler condenser assembly with the bolt.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  27. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the discharge hose sub-assembly and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  28. INSTALL FRONT BUMPER REINFORCEMENT

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  29. CONNECT AMBIENT TEMPERATURE SENSOR ASSEMBLY

    1. Attach the clamp to connect the ambient thermistor assembly.

  30. INSTALL LOWER RADIATOR AIR GUIDE PLATE

    1. Install the lower radiator guide plate and attach the 3 claws.

  31. INSTALL UPPER RADIATOR AIR GUIDE PLATE

    1. Install the upper radiator air guide plate with 6 clips.

  32. INSTALL FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY

    1. Install the front bumper upper reinforcement sub-assembly with the 2 bolts.

      Tip:

      A bolt without a torque specification is shown in the standard bolt chart.

      Click here

  33. INSTALL FRONT BUMPER CENTER STAY SUB-ASSEMBLY

    1. Install the front bumper center stay sub-assembly with the 2 bolts and clip.

      Tip:

      A bolt without a torque specification is shown in the standard bolt chart.

      Click here

  34. INSTALL LOW PITCHED HORN ASSEMBLY

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  35. INSTALL HIGH PITCHED HORN ASSEMBLY

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  36. INSTALL BATTERY BRACKET REINFORCEMENT

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  37. INSTALL FRONT BATTERY BRACKET

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  38. INSTALL BATTERY TRAY

  39. INSTALL BATTERY

  40. INSTALL BATTERY INSULATOR

  41. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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  42. INSTALL FRONT LOWER BUMPER ABSORBER

    1. Install the front lower bumper absorber with the 4 screws.

  43. INSTALL HEADLIGHT ASSEMBLY

  44. INSTALL FRONT BUMPER COVER

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  45. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick here

  47. ADD ENGINE COOLANT

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  48. CHARGE REFRIGERANT

    Click hereClick here

  49. WARM UP ENGINE

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  50. INSPECT FOR REFRIGERANT LEAK

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  51. ADJUSTMENT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

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  52. INSPECT FOR COOLANT LEAK

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  53. INSTALL NO. 1 ENGINE COVER

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  54. INSTALL NO. 1 ENGINE UNDER COVER

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