User's Manual

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

V. A hole approximately Ø1" will have to be made

into the lower front plastic valance for the water

line to pass through. Locate the point where the

hose is to pass through and create a hole using

a hole saw or grinder.

W. Reinstall the lower front valance and attach the

passenger side only, leaving the drivers side

loose. Attach the hose previously cut between

the water reservoir and the water pump inlet and

secure with the provided clamps. (See

Fig. 12-m.

)

X. Temporarily plug the 90° fitting attached to the

driver side of the charge air cooler that connects

to the water cooler outlet hose. Leave the hose

that comes from the top fitting of the water cooler

open to atmosphere.

Y. Fill the system at the charge air cooler with 1/4 -

1/3 of a gallon of anti-freeze.

Slowly

fill the

remainder with water until it comes out of the

open hose coming from the top of the water

cooler, this will help to purge the system of air.

Connect the hose coming from the top fitting on

the water cooler to the open fitting on the charge

air cooler and secure with the provided clamp.

Continue to fill the system with water until it is full

and install the cap onto the charge air cooler.

Z. With the battery reconnected, key the vehicle to

the ON position. Slowly remove the cap on the

charge air cooler and check the level of the

coolant and make sure the coolant is flowing

through the system. Run the system for a few

minutes to allow any air trapped in the lower part

of the system to escape. Top the system off with

coolant if necessary and reinstall the cap.

12. CHARGE AIR COOLER INSTALLATION, cont’d.

Fig. 12-i

Fig. 12-k

Fig. 12-l

Fig. 12-m

Fig. 12-j