RADIATOR REMOVAL

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

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2. 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.

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note:

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

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4. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

5. REMOVE NO. 1 ENGINE UNDER COVER

   1. 

      Remove the 4 bolts and 2 screws.

   2. Remove the 10 clips and No. 1 engine under cover.

6. DRAIN ENGINE COOLANT

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7. REMOVE HEADLIGHT ASSEMBLY

   • for Halogen Headlight

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   • for LED Headlight

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8. REMOVE FRONT LOWER BUMPER ABSORBER

   1. 

      Remove the 4 screws and front lower bumper absorber.

9. REMOVE NO. 1 ENGINE COVER

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10. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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11. REMOVE BATTERY INSULATOR

12. REMOVE BATTERY

13. REMOVE BATTERY TRAY

14. REMOVE BATTERY CARRIER ASSEMBLY

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15. REMOVE BATTERY BRACKET REINFORCEMENT

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16. REMOVE FRONT BUMPER CENTER STAY SUB-ASSEMBLY

    1. 

       Disconnect the connector from the horn.

    2. Remove the 2 bolts and front bumper center stay sub-assembly.

17. REMOVE FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY

    1. 

       Disconnect the connector from the horn.

    2. Remove the 2 clips, 2 bolts and front bumper upper reinforcement sub-assembly.

18. REMOVE UPPER RADIATOR AIR GUIDE PLATE

    1. 

       Remove the 6 clips and upper radiator air guide plate.

19. REMOVE LOWER RADIATOR AIR GUIDE PLATE

    1. 

       Detach the 3 claws and remove the lower radiator air guide plate.

20. REMOVE FRONT BUMPER REINFORCEMENT

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

    

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

    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.

22. DISCONNECT LIQUID TUBE SUB-ASSEMBLY (w/ Air Conditioning System)

    

    1. Remove the bolt and disconnect the liquid tube sub-assembly from the cooler condenser assembly.

    2. Remove the O-ring from the liquid tube sub-assembly.

       Note:

       Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

23. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE RH

    1. 

       Detach the 3 claws and remove the front radiator side air guide plate RH.

24. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE RH

    1. 

       Remove the 2 clips and rear radiator side air guide plate RH.

25. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE LH

    1. 

       Detach the 3 claws and remove the front radiator side air guide plate LH.

26. REMOVE REAR RADIATOR SIDE AIR GUIDE PLATE LH

    1. 

       Remove the 2 clips and rear radiator side air guide plate LH.

27. REMOVE NO. 1 RADIATOR SUPPORT

    1. Remove the 2 bolts and 2 No. 1 radiator supports.

       

    2. Remove the 2 radiator support cushions.

28. DISCONNECT WATER BY-PASS HOSE ASSEMBLY

    1. 

       Slide the clamp and disconnect the water by-pass hose assembly from the radiator reservoir assembly.

    2. Detach the clamp to remove the No. 5 water by-pass hose from the hose clamp bracket

    3. Remove the bolt and disconnect the water by-pass hose assembly from the upper radiator support sub-assembly.

29. DISCONNECT WIRE HARNESS

    1. 

       Disconnect the 3 connectors and detach the 10 wire harness clamps.

30. REMOVE HOOD LOCK ASSEMBLY

    • for LHD

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    • for RHD

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31. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY

    1. 

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

32. DISCONNECT NO. 5 WATER BY-PASS HOSE

    1. 

       Detach the clamp to disconnect the No. 5 water by-pass hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 5 water by-pass hose from the radiator assembly.

33. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    1. 

       Slide the hose clamp and disconnect the No. 2 radiator hose sub-assembly from the radiator assembly.

34. DISCONNECT NO. 1 RADIATOR HOSE

    1. 

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

35. REMOVE NO. 2 AIR HOSE

    1. 

       Loosen the hose clamp and disconnect the No. 2 air hose from the intercooler assembly.

36. REMOVE NO. 3 AIR HOSE

    1. 

       Loosen the hose clamp and disconnect the No. 3 air hose from the No. 2 air tube.

37. DISCONNECT NO. 2 RADIATOR HOSE

    1. 

       *a

       Retainer

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

38. REMOVE RADIATOR ASSEMBLY

    1. 

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

       Note:

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

    2. Remove the 2 cushions.

39. REMOVE NO. 2 AIR TUBE

    1. 

       Loosen the hose clamp and remove the bolt and No. 2 air tube from the intercooler assembly.

40. REMOVE NO. 2 RADIATOR HOSE

    1. 

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

41. REMOVE UPPER RADIATOR SUPPORT

    1. Remove the 4 bolts and 2 upper radiator supports.

       

42. REMOVE COOLER CONDENSER ASSEMBLY

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43. REMOVE NO. 2 RADIATOR SUPPORT

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44. REMOVE INTERCOOLER ASSEMBLY

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45. REMOVE FAN SHROUD

    1. 

       Remove the 3 bolts and fan shroud.

46. REMOVE NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    1. Detach the clamp to remove the No. 2 radiator hose sub-assembly.