Remove Exterior Parts

1. Remove the engine cover.

A. Remove the nuts.

B. Remove the cover unit.





2. Remove the engine compartment side cover RH.

A. Disengage the clip.

B. Remove the engine compartment side cover.





3. Disconnect the negative (-) battery terminal.





4. Recover refrigerant system HFC-134a (R-134a).

Equipment: Robinair R-134a
Refrigerant Recovery/Recycling
Machine (P/N R0B342000)

Refer to the Technical Information System (TIS), 2004 model year GX 470 Repair Manual: Heater & Air Conditioner: Air Conditioning System: Precaution.





5. Remove the radiator support seal upper.

A. Disengage the 12 clips.

B. Remove the cover.





6. Remove the front bumper assembly.

A. Disengage the 3 clips and remove the 4 bolts and 8 screws.

B. Disconnect the fog lamp connectors.

C. Remove the bumper.





7. Remove the hood seal of the radiator support.





8. Remove the air cleaner assembly.

A. Remove the throttle with motor body assembly connector.

B. Remove the throttle with motor body assembly connector bracket.

C. Remove the air cleaner hose from the air cleaner cover.

D. Remove the upper air cleaner cover.

E. Remove the air cleaner.

F. Remove the 3 bolts.

G. Remove the lower air cleaner box.





9. Remove the ground terminal. Remove the bolt located at the RH front fender.





10. Remove the front RH and LH bumper stay.

A. Remove the 2 bolts.

B. Remove the 2 nuts.





11. Remove the front RH and LH headlamp assembly.

A. Remove the bolt cap.

B. Remove the bolt.

C. Disconnect the headlamp connectors.

D. Remove the headlamp assembly.





12. Remove the front bumper retainer and bracket center.

A. Remove the 2 bolts.

B. Remove the retainer and bracket together as one unit.





13. Remove the power steering fluid reserve tank.

Draining the reserve tank is unnecessary.

Disconnect the reserve tank from the bracket.

It is NOT necessary to remove the reserve tank. Place the tank so that it does NOT cause an obstruction.





14. Remove the skid control sensor wire harness bracket and connector (right engine compartment).

A. Remove the 2 brackets.

B. Disconnect the 2 wire harness connectors.





15. Remove the quick disconnect joint from the accessory A/C tube assembly.

Using the SST, remove the 2 quick disconnect joints (refer to the illustrations).

^ SST P/N: 09870-00005-02








16. Remove the quick disconnect joint from the tube sub-accessory at the condenser (front side).

Using the SST, remove the 2 quick disconnect joints (refer to the illustrations).

SST P/N: 09870-00005-02





17. Remove the bolt from the condenser line bracket (front side).





18. Disconnect the A/C pressure switch connector.

A. Disconnect the 2 pressure switch connectors (high and low).

B. Remove the clip.





19. Remove the nut and the NC suction hose.





20. Remove the front accessory A/C tube.

A. Remove the nut and bolt.

B. Remove the pipe.

C. Remove the foam seal between the line and the core support.

NOTE:

^ Do NOT reuse the pipe and seal.

^ Using a scraper (or equivalent), remove any remaining seal.





21. Remove the A/T oil cooler hoses.

NOTE:

^ Prepare a waste cloth in case of A/T oil leakage.

^ Avoid A/T fluid loss.

A. Disengage the 2 clamps.

B. Remove the A/T cooler assembly.

22. Remove the A/T oil cooler.

A. Remove the 3 bolts.

B. Remove the oil cooler.





23. Remove the condenser brackets from the radiator support.

A. Remove the 6 bolts from the condenser side.

B. Remove the condenser brackets.

NOTE:
Save these brackets for use in step 44 of the "Remove exterior parts section" of the Repair Procedure.





24. Remove the condenser. Slide the condenser core out through the underside of the vehicle.





25. Remove the radiator reserve tank.

NOTE:
Draining the coolant in the tank and removing the hose is unnecessary.

A. Remove the 3 bolts.

B. Place the reserve tank temporarily on the engine.





26. Remove the front fender apron seal clip.

Disengage the 2 upper clips from the front fender apron seal LH.

NOTE:
Kinetic suspension fender apron will slightly differ in configuration based on model year.

HINT:
For convenience, it may be necessary to raise the vehicle and remove the front left tire to access this area.





27. Remove the A/C suction hose nut. Using the extension bar, remove the nut through the upper cover from the left front tire opening.

HINT:

For convenience, remove the wire harness bracket located on the compressor to gain access to the compressor line nut.





28. Remove the A/C suction hose bracket.

A. Remove the wire harness bracket bolt under the engine (in front of the oil pan).

B. Remove the suction hose through the underside of the vehicle.





29. Remove the accessory A/C tube assembly nuts at the pipe joint.

HINT:

For convenience, it may be necessary to move the exhaust shield to gain access to this point.





30. Remove the front fender apron seal clips.

Disengage the 2 upper clips from the front fender apron seal RH.

HINT:

For convenience, it may be necessary to raise the vehicle and remove the front right tire to access this area.





31. Remove the bracket on the accessory NC tube assembly.





32. Remove the accessory A/C tube assembly.

A. Remove the pipe from the engine compartment.





B. Remove the A/C pipe grommet.

33. Raise the vehicle.





34. Remove the front bumper cover lower.

A. Disengage the 2 clips and remove the 5 bolts.

B. Remove the cover.





35. Remove the engine under cover No. 1.

A. Remove the 4 bolts.

B. Remove the cover.





36. Remove the engine under cover No. 2.

A. Remove the 4 bolts.

B. Remove the cover.

37. Lower the vehicle.





38. Remove the 4 bolts from the radiator, tilt the radiator back, and support it.





39. Install the radiator seal (upper side). Seal Packing: P/N 36867-60040

A. Fit the upper seal to the lower position of the radiator installation boss before attaching as shown in the illustration.

B. Attach to the front side.

NOTE:
Do NOT damage the radiator fins.





40. Install the radiator seal packing (lower side).

Seal Packing: P/N 36867-60040

A. Fit the lower seal to the end of the radiator side before attaching as shown in the illustration.

B. Attach to the front side.

NOTE:
Do NOT damage the radiator fins.

41. Install the seal packing between the front chassis cross member and the radiator.

NOTE:

^ If TSB No. AC001-04, "A/C Performance Improvement," has been performed on the vehicle, this seal may already be present.

^ If the seal is already installed in this location, do NOT perform this step.

Seal Packing: P/N 88578-60330 (30x15x720 mm)





42. Resecure the radiator to the vehicle.

NOTE:

Do NOT damage the radiator fins.
Tighten the 4 bolts.

Torque: 18 N.m
(184 kgf.cm, 159 in.lbf)





43. Install the A/C condenser. Carefully slide the condenser core up into place and support the condenser to avoid any damage to the fins or condenser and radiator assembly.

Core Condenser: P/N 88461-60111





44. Install the brackets to the condenser and install the condenser assembly to the vehicle.

A. Install the 4 condenser brackets to the condenser.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

NOTE:
Install the brackets removed in step 23.

B. Install the condenser assembly to the vehicle.