Intercooler Removal

Remove the 11 clips and intake duct seal.

Remove the bolt, clip and inlet air cleaner.

Remove the No. 1 engine cover.

Remove the radiator cap.

Loosen the radiator drain cock plug and cylinder block drain cock plug. Then drain the coolant.

HINT:

Collect the coolant in a container and dispose of it according to local regulations.

Using a screwdriver, turn the pin 90 degrees and remove the 2 pin hold clips.

HINT:

1. Tape the screwdriver tip before use.
   
2. Use the same procedures for the RH side and LH side.
   

Put protective tape around the front bumper assembly.

Using a clip remover, remove the 2 clips

Remove the 2 radiator grille protectors.

Remove the bolt and 10 screws.

Disengage the 5 claws and disconnect the front bumper assembly as shown in the illustration.

HINT:

Use the same procedures for the RH side and LH side.

Disconnect the headlight washer hose. (w/ headlight cleaner system)

Disconnect the connector and remove the front bumper assembly.

Remove the front bumper energy absorber.

Loosen the clip and disconnect the reserve tank outlet hose.

Loosen the clip and disconnect the reserve tank hose.

Remove the 2 bolts and radiator reserve tank.

Remove the 3 screws, clamp and the hood lock control cable cover.

Disconnect the connector.

Remove the hood lock nut cap and the hood lock nut.

Remove the 2 bolts and separate the hood lock assembly from the upper radiator support.

NOTICE:

Do not forcibly bend the hood lock control cable.

Separate the 4 wire harness clamps and disconnect the 2 connectors.

Separate the clamp and disconnect the 2 cooling fan motor connectors.

Separate the 6 clamps and the No. 2 engine room wire.

Remove the 5 bolts and the upper radiator support.

Loosen the 2 clips and remove the radiator inlet hose.

Loosen the 2 clips and remove the air tube.

Loosen the clip and remove the No. 2 air hose.

Loosen the clip and disconnect the vacuum transmitting hose.

Loosen the clip and disconnect the radiator outlet hose.

Loosen the clip and disconnect the No. 3 air hose.

Remove the 4 bolts and disconnect the intercooler and radiator assembly from the cooler condenser.

Remove the radiator assembly from the vehicle together with the intercooler and cooling fan assembly.

NOTICE:

Make sure that the cooler condenser assembly and radiator assembly do not come into contact with each other.

Loosen the clip and disconnect the radiator outlet hose.

Remove the 3 bolts and the vacuum transmitting pipe.

Loosen the clip and disconnect the vacuum transmitting pipe.

Remove the 4 bolts and intercooler from the radiator assembly.