SUB-Tank and Installation Procedure Information

EXPLANATION OF SUB-TANK DESCRIBED HEREAFTER


New Type - radiator sub-tank mounted in front of the radiator Old Type - radiator sub-tank mounted on left front suspension tower



INSTALLATION PROCEDURE

NOTE:
Hoses furnished in kit are high pressure hoses and must be installed as indicated in the instructions.
1. Remove the air cleaner fresh air duct.

2. Remove the sub-tank (new type only).

3. Remove the radiator duct panel (right side).

4. Remove the bolts which fasten the air cleaner assembly.

5. Remove the water hose between the radiator cap and the sub-tank.




6. Replace the filler neck and the O-ring with new ones (N323 15 175, N326 15 174). Install the radiator cap onto the new filler neck.




7. A) Vehicle with New Type Sub-Tank

Install water hose (N320 15 54Y) through the sub-tank hose hole in the shroud panel (right side).

CAUTION:
Make sure the water hose is not kinked or bent too sharply.



B) Vehicle with Old Type Sub-Tank

Install the two water hoses (N320 15 54Y and 9932 50 7650) through the air conditioner pipe hole in the shroud panel.

NOTE:
1. Apply soapy water to the water hose before installation.
2. Vehicles without air conditioning require grommet (BA70 61 218) to be installed on the shroud panel for the water hoses to be inserted through.

CAUTION:
Make sure the water hose is not kinked or bent too sharply.



8. Replace the level sensor with the modified one and connect the water hose (N320 15 54Y) with the hose clamp (9928 21 301).

CAUTION:
When installing the modified level sensor, turn the level sensor until the rubber seal slightly touches the radiator. Then tighten 3/4 to 1-3/4 turns, aligning the open end of the pipe to the right side. When tightening the sensor, DO NOT turn the sensor counter clockwise to position the end of the water pipe. You must tighten the sensor beyond the 3/4 turn if necessary to align the water pipe.



9. Install the two bolts (9979 60 625) and washers (2850 13 332) on the shroud panel (right side). The vehicles equipped with an an conditioner require replacement of the receiver dryer bracket mounting bolts with new ones (9979 60 625).




NOTE:
On vehicles equipped with an air conditioner, install the washers (2850 13 332) between the bracket of the receiver dryer and the shroud panel as shown at right.



10. Install the water hose (N320 15 54Y) onto the bottom pipe of the radiator cap assembly (N320 15 02YA) and fasten it with a hose clamp (9928 21 301).




11. Install the radiator cap assembly over the bolts mentioned in procedure 9 and fasten it with washers (2850 13 332) and nuts (9994 00 600).










12. Reinstall the radiator duct panel (right side).

13. Reinstall the sub-tank (new type only).

14. Connect the water hose from the sub-tank to the radiator cap assembly.

15. Fasten the air cleaner assembly with bolts.

16. Reinstall the fresh air duct.