RADIATOR INSTALLATION

PROCEDURE

  1. INSTALL RADIATOR DRAIN COCK PLUG

    1. Install the O-ring to the radiator drain cock plug.

      Note:

      Replace the O-ring if it is damaged.

    2. Install the radiator drain cock plug.

  2. INSTALL RADIATOR ASSEMBLY

    1. Engage the 2 claws and install the radiator assembly to the fan shroud assembly.

      Note:

      Do not damage the radiator assembly when installing the fan shroud assembly.

    2. Install the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

    3. Install the water by-pass hose to the radiator assembly and slide the clip to secure it.

    4. Install the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.

    5. Engage the 2 clamps to connect the No. 1 radiator hose to the fan shroud assembly.

    6. Install the No. 2 water by-pass hose to the radiator assembly and slide the clip to secure it.

  3. INSTALL INTERCOOLER COOLING RADIATOR ASSEMBLY

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  4. INSTALL RADIATOR ASSEMBLY AND FAN SHROUD ASSEMBLY

    1. Install the 2 lower radiator supports.

    2. Install the radiator assembly and fan shroud assembly to the vehicle body.

    3. Engage the 4 wire harness clamps.

    4. Connect the cooling fan ECU connector.

  5. INSTALL NO. 2 FAN SHROUD

    1. Engage the 3 claws.

    2. Install the No. 2 fan shroud to the radiator assembly with the 2 bolts.

      10.5 N*m

      107 kgf*cm

      8 ft.*lbf

    3. Engage the 4 clamps to connect the No. 2 water by-pass hose to the No. 2 fan shroud.

  6. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

    1. Install the upper radiator support sub-assembly with the 4 bolts.

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

    2. for RHD:

      1. Engage the clamp to connect the wire harness to the upper radiator support sub-assembly.

      2. Engage the 2 clamps to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

    3. for LHD:

      1. Engage the clamp to connect the wire harness to the upper radiator support sub-assembly. (w/ Engine Hood Courtesy Switch)

      2. Engage the 2 clamps to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

  7. INSTALL UPPER RADIATOR SUPPORT

    1. Install the radiator support cushion to each upper radiator support.

    2. Install the 2 upper radiator supports with the 2 bolts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

  8. CONNECT NO. 1 RADIATOR HOSE

    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

  9. CONNECT NO. 2 RADIATOR HOSE

    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

  10. CONNECT NO. 2 INTERCOOLER WATER HOSE

    1. Connect the No. 2 intercooler water hose to the intercooler reserve tank assembly and slide the clip to secure it.

  11. CONNECT NO. 1 WATER BY-PASS HOSE

    1. Connect the No. 1 water by-pass hose to the intercooler reserve tank assembly and slide the clip to secure it.

    2. Engage the clamp to connect the No. 1 water by-pass hose to the No. 2 intercooler water hose.

  12. CONNECT NO. 2 WATER BY-PASS HOSE

    1. Engage the clamp to connect the No. 2 water by-pass hose to the upper radiator support sub-assembly.

    2. Connect the No. 2 water by-pass hose to the intercooler reserve tank assembly and slide the clip to secure it.

  13. INSTALL THERMISTOR ASSEMBLY

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  14. INSTALL BATTERY TRAY

    1. Install the battery tray.

  15. INSTALL BATTERY

    1. Install the battery.

    2. Install the battery insulator to the battery.

    3. Install the battery clamp sub-assembly with the battery clamp bolt, bolt and nut.

      Bolt

      16.5 N*m

      168 kgf*cm

      12 ft.*lbf

      Nut

      3.5 N*m

      36 kgf*cm

      31 in.*lbf

    4. Connect the cable to the positive (+) battery terminal and tighten the nut.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  16. INSTALL ELECTRIC WATER PUMP ASSEMBLY

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  17. CONNECT NO. 3 TURBO WATER HOSE

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  18. CONNECT NO. 4 TURBO WATER HOSE

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  19. INSTALL CONDENSER WITH RECEIVER ASSEMBLY (w/ Air Conditioning System)

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  20. CONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Air Conditioning System)

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

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  22. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY

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  23. INSTALL NO. 3 RADIATOR AIR GUIDE

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  24. INSTALL HOOD LOCK ASSEMBLY

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  25. INSTALL HEADLIGHT ASSEMBLY LH

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  26. INSTALL HEADLIGHT ASSEMBLY RH

    Tip:

    Use the same procedure as for the LH side.

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  28. ADD ENGINE COOLANT

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  29. ADD ENGINE COOLANT (for Intercooler)

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  30. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)

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  31. INSPECT FOR COOLANT LEAK

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  32. INSPECT FOR COOLANT LEAK (for Intercooler)

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  33. WARM UP ENGINE (w/ Air Conditioning System)

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  34. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

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