7GR-FKS COOLING  RADIATOR  INSTALLATION  

Install the 2 lower radiator supports to the radiator assembly.

w/ Air Conditioning System:

i.

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Install in this Direction

Install the radiator assembly to the vehicle as shown in the illustration.

NOTICE:

·

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

·

When installing the radiator assembly, do not damage the cooler condenser assembly.

w/o Air Conditioning System:

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Install in this Direction

Install the radiator assembly to the vehicle as shown in the illustration.

NOTICE:

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

Connect the oil cooler outlet hose to the radiator assembly, and slide the clip to secure the hose.

NOTICE:

Make sure the oil cooler outlet hose is securely inserted to the stopper.

6.375,2.031 6.115,1.667 true 3.927,1.573 3.479,2.167 true 3.177,1.604 3.49,1.76 0.313,0.156 10 false *a 3.354,2.177 3.667,2.333 0.313,0.156 10 false *b 3.854,0.542 4.167,0.698 0.313,0.156 10 false *c 5.833,0.688 6.146,0.844 0.313,0.156 10 false *e 5.813,2.042 6.125,2.198 0.313,0.156 10 false *f 6.375,2.052 6.583,2.281 0.208,0.229 10 false *1 6.656,1.76 6.969,1.917 0.313,0.156 10 false *d 4.552,1.615 4.865,1.771 0.313,0.156 10 false *a 6.531,1.375 6.844,1.531 0.313,0.156 10 false *c

*1	Radiator Assembly	-	-
*a	45°	*b	Paint Mark
*c	Upper Side	*d	Front Side
*e	0 to 3 mm (0 to 0.118 in.)	*f	2 to 5 mm (0.0787 to 0.197 in.)

Connect the oil cooler inlet hose to the radiator assembly, and slide the clip to secure the hose.

NOTICE:

Make sure the oil cooler inlet hose is securely inserted to the stopper.

6.375,2.031 6.115,1.667 true 3.917,1.563 3.604,2.167 true 3.177,1.604 3.49,1.76 0.313,0.156 10 false *a 3.469,2.188 3.781,2.344 0.313,0.156 10 false *b 3.854,0.552 4.167,0.708 0.313,0.156 10 false *c 5.833,0.688 6.146,0.844 0.313,0.156 10 false *e 5.813,2.052 6.125,2.208 0.313,0.156 10 false *f 6.375,2.052 6.583,2.281 0.208,0.229 10 false *1 6.646,1.76 6.958,1.917 0.313,0.156 10 false *d 4.552,1.604 4.865,1.76 0.313,0.156 10 false *a 6.531,1.354 6.844,1.51 0.313,0.156 10 false *c

*1	Radiator Assembly	-	-
*a	45°	*b	Paint Mark
*c	Upper Side	*d	Front Side
*e	0 to 3 mm (0 to 0.118 in.)	*f	2 to 5 mm (0.0787 to 0.197 in.)

for LHD:

i.

2.417,0.875 2.594,0.323 true 2.24,1.667 1.708,1.531 true 2.229,1.625 2.458,1.792 0.229,0.167 10 true *1 2.521,0.156 2.74,0.333 0.219,0.177 10 true *2

*1	Engine Room Main Wire
*2	Hood Lock Control Cable Assembly

Attach the clamps to connect the engine room main wire and hood lock control cable assembly.

for RHD:

i.

0.656,1.458 1.073,1.042 true 2.229,1.625 1.771,1.521 true 2.198,1.573 2.417,1.729 0.219,0.156 10 true *1 0.479,1.448 0.708,1.625 0.229,0.177 10 true *2

*1	Engine Room Main Wire
*2	Hood Lock Control Cable Assembly

Attach the clamps to connect the engine room main wire and hood lock control cable assembly.

0.938,1.74 1.208,1.396 true 0.781,1.719 1,1.885 0.219,0.167 10 true *1

*1	Engine Room Main Wire

Install the bolt to connect the engine room main wire.

Torque:

11.5 N*m (117 kgf*cm, 8 ft.*lbf)

Attach the guides to install the radiator protector.

Install the 4 bolts.

Torque:

7.5 N*m (76 kgf*cm, 66 in.*lbf)

Install the center front bumper brace with the 2 bolts.

Torque:

15 N*m (153 kgf*cm, 11 ft.*lbf)

Attach the claws to install the radiator side air seal RH.

Attach the claw and clip to install the radiator side air seal LH.

Install the hood lock support brace sub-assembly with the 2 bolts.

Torque:

8.5 N*m (87 kgf*cm, 75 in.*lbf)

w/ Air Conditioning System:

i.

2.729,1.552 2.448,1.042 true 2.688,1.552 2.896,1.719 0.208,0.167 10 true *1

*1	Air Conditioner Tube and Accessory Assembly

Attach the clamp to connect the air conditioner tube and accessory assembly.

2.281,0.865 2.906,0.677 true 2.896,0.563 3.115,0.719 0.219,0.156 10 true *1

*1	Engine Room Main Wire

Attach the clamps to connect the engine room main wire.

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Install in this Direction

Place the fan shroud together with the fan with fluid coupling assembly between the engine and radiator assembly.

NOTICE:

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

Temporarily install the fan with fluid coupling assembly to the water pump assembly with the 4 nuts.

NOTICE:

·

Make sure to match the paint mark colors on the fan with fluid coupling assembly with the stud bolts of the same color on the water pump assembly.

·

When installing the fan and fan and generator V belt, make sure to securely tighten the nuts of the fan with fluid coupling assembly so that the fan pulley is properly aligned.

Attach the guides to install the fan shroud.

for Automatic Transmission:

i.

Attach the clamp to connect the oil cooler inlet hose.

Attach the claws.

Tighten the 4 nuts holding the fan with fluid coupling assembly.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Connect the No. 2 radiator hose to the radiator assembly, and slide the clip to secure the hose.

NOTICE:

·

Make sure the No. 2 radiator hose is securely inserted to the stopper.

·

Position the clip so that it is 2 to 5 mm (0.0787 to 0.197 in.) away from the end of the water hose.

·

Install so that the No. 2 radiator hose paint mark is aligned with the protrusion of the radiator assembly.

5.729,0.646 4.896,0.74 true 6.438,2.406 5.771,2.271 true 3.948,1.656 3.688,2.292 true 3.281,0.427 3.594,0.583 0.313,0.156 10 false *a 4.198,2.01 4.51,2.167 0.313,0.156 10 false *b 3.573,2.292 3.885,2.448 0.313,0.156 10 false *c 3.885,0.635 4.198,0.792 0.313,0.156 10 false *d 6.385,1.781 6.698,1.938 0.313,0.156 10 false *e 6.677,1.521 6.99,1.677 0.313,0.156 10 false *f 3.135,1.208 3.344,1.438 0.208,0.229 10 false *g 1.677,1.406 1.813,1.594 0.135,0.188 10 true A 6.396,1.292 6.708,1.448 0.313,0.156 10 false *d 4.708,0.667 5.021,0.823 0.313,0.156 10 false *c 6.479,2.333 6.688,2.563 0.208,0.229 10 false *h

*a	View A	*b	90°
*c	Paint Mark	*d	Upper Side
*e	Front Side	*f	RH Side
*g	LH Side	*h	Protrusion of the Radiator Assembly

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

NOTICE:

·

Make sure the No. 2 radiator hose is securely inserted to the stopper.

·

Position the clip so that it is 2 to 5 mm (0.0787 to 0.197 in.) away from the end of the water hose.

·

Install so that the No. 2 radiator hose paint mark is aligned with the protrusion of the water inlet sub-assembly with thermostat.

5.094,1.521 4.958,1.01 true 6.406,1.083 6.271,0.573 true 4.25,0.563 3.938,1.219 true 3.313,0.406 3.625,0.563 0.313,0.156 10 false *a 3.531,0.74 3.844,0.896 0.313,0.156 10 false *b 4.208,0.396 4.521,0.552 0.313,0.156 10 false *c 3.844,0.51 4.156,0.667 0.313,0.156 10 false *d 6.135,1.979 6.448,2.135 0.313,0.156 10 false *e 6.698,1.938 7.01,2.094 0.313,0.156 10 false *f 6.167,0.375 6.375,0.604 0.208,0.229 10 false *g 1.031,1.333 1.167,1.521 0.135,0.188 10 true A 6.375,1.74 6.688,1.896 0.313,0.156 10 false *d 4.854,0.844 5.167,1 0.313,0.156 10 false *c

*a	View A	*b	90°
*c	Paint Mark	*d	Upper Side
*e	Front Side	*f	RH Side
*g	Protrusion of the Water Inlet Sub-assembly with Thermostat	-	-

Install the No. 1 radiator hose to the water outlet, and slide the clip to secure the hose.

NOTICE:

·

Make sure the No. 1 radiator hose is securely inserted to the stopper.

·

Position the clip so that it is 2 to 5 mm (0.0787 to 0.197 in.) away from the end of the water hose.

·

Install so that the No. 1 radiator hose paint mark is aligned with the protrusion of the water outlet.

5.219,0.635 5.823,0.844 true 6.156,2.323 5.49,2.188 true 4.427,0.781 4.146,1.208 true 3.313,0.406 3.625,0.563 0.313,0.156 10 false *a 3.438,0.927 3.75,1.083 0.313,0.156 10 false *b 4.406,0.625 4.719,0.781 0.313,0.156 10 false *c 4.052,0.521 4.365,0.677 0.313,0.156 10 false *d 6.271,1.51 6.583,1.667 0.313,0.156 10 false *e 6.188,2.24 6.396,2.469 0.208,0.229 10 false *g 1.875,0.917 2.01,1.104 0.135,0.188 10 true A 6.51,1.271 6.823,1.427 0.313,0.156 10 false *d 5.063,0.51 5.375,0.667 0.313,0.156 10 false *c 6.781,1.635 7.01,1.802 0.229,0.167 10 false *f 3.115,1.479 3.427,1.635 0.313,0.156 10 false *e

*a	View A	*b	90°
*c	Paint Mark	*d	Upper Side
*e	Front Side	*f	RH Side
*g	Protrusion of the Water Outlet	-	-

Connect the No. 1 radiator hose to the radiator assembly, and slide the clip to secure the hose.

NOTICE:

·

Make sure the No. 1 radiator hose is securely inserted to the stopper.

·

Position the clip so that it is 2 to 5 mm (0.0787 to 0.197 in.) away from the end of the water hose.

·

Install so that the No. 1 radiator hose paint mark is aligned with the protrusion of the radiator assembly.

5.875,2.208 6.271,1.552 true 5.167,1.135 5.031,0.625 true 4.24,0.583 3.927,1.24 true 3.313,0.406 3.625,0.563 0.313,0.156 10 false *a 3.531,0.729 3.844,0.885 0.313,0.156 10 false *b 4.208,0.417 4.521,0.573 0.313,0.156 10 false *c 3.844,0.49 4.156,0.646 0.313,0.156 10 false *d 6.01,0.51 6.323,0.667 0.313,0.156 10 false *e 6.708,0.417 7.021,0.573 0.313,0.156 10 false *f 4.927,0.417 5.135,0.646 0.208,0.229 10 false *g 0.865,1.083 1,1.271 0.135,0.188 10 true A 6.385,0.188 6.698,0.344 0.313,0.156 10 false *d 5.76,2.198 6.073,2.354 0.313,0.156 10 false *c

*a	View A	*b	90°
*c	Paint Mark	*d	Upper Side
*e	Front Side	*f	RH Side
*g	Protrusion of the Radiator Assembly	-	-

0,0 0,0 false

	Radiator Reserve Tank Hose
	Bolt

Install the radiator reserve tank assembly with the 2 bolts.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

Install the 2 bolts to connect the vane pump oil reservoir assembly.

Torque:

4.5 N*m (46 kgf*cm, 40 in.*lbf)

Install the No. 1 air cleaner inlet with the 2 bolts.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)