ActyonA0A06004.pdf

CHANGED BYEFFECTIVE DATE

AFFECTED VIN

COOLING SYSTEMACTYON SM - 2006.03

1506

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Coolant Hose (Inlet/Outlet)Preceding Work: Draining of coolant

1. Loosen the clamp and remove the coolant outlet hose(engine to radiator).

2. Disconnect the HFM sensor connector.3. Remove the air intake duct from the air cleaner.

4. Loosen the clamp and remove the coolant inlet hose(radiator to thermostat housing).

REMOVAL AND INSTALLATION



AFFECTED VIN

16 06

Shroud and Cooling Fan/ClutchPreceding Work:1. Draining of coolant2. Removal of coolant inlet and outlet hose

1. Remove the air cleaner duct.

2. Release the clamps and remove the intake hose.3. Unscrew the fan shroud mounting bolts.

5. Lift up the vehicle and remove the skid plate.6. Loosen the clamp and remove the lower inlet hose.


AFFECTED VIN


1706

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6. Remove the shroud.7. Install in the reverse order of removal.

5. Unscrew the center bolt and remove the cooling fanclutch while holding the pulley with counter holder(special tool).Installation Notice

45 4.5 NmTightening torque



AFFECTED VIN

18 06

Preceding Works: 1. Draining of coolant2. Removal of V-belt3. Removal of shroud4. Removal of cooling fan

1. Thermostat housing2. Gasket ........................................................ Replace3. Bolt ................................................................ 10 Nm

4. Belt pulley5. Bolt ................................................................ 10 Nm6. Water pump bearing housing

Water Pump - Assembly


AFFECTED VIN


1906

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1. Remove the V-belt while pressing down the autotensioner adjusting bolt.

2. Unscrew the bolts and remove the EGR pipe andbracket.

Installation Notice

Tightening torque 23 2.3 Nm

3. Unscrew the bolts and remove the belt pulley whileholding the belt pulley with a special tool.

Installation Notice

Tightening torque 10 Nm



AFFECTED VIN

20 06

5. Unscrew the bolts and remove the water pumpassembly.

Installation Notice

6. Install in the reverse order of removal.


Replace the O-ring in oil dipstick with new one. Plug the oil dipstick hole with a cap not to get the

foreign materials into the engine.

NOTICE

Remove the gasket residues from the sealing sur-face and replace the gasket with new one.

NOTICE


AFFECTED VIN


2106

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Preceding Works: 1. Draining of coolant2. Removal of V-belt3. Removal of cooling fan4. Removal of intake duct (air cleaner to turbo charger)

1. Gasket ...................................................... Replace2. Water pump housing3. Bolt .............................................................. 10 Nm

4. Thermostat5. Seal6. Coolant hose

Thermostat



AFFECTED VIN

22 06

1. Unscrew the bolts and remove the thermostat housing.

Installation Notice

2. Remove the thermostat.3. Install in the reverse order of removal.



AFFECTED VIN


2306

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Water Pump HousingPreceding Works:1. Removal of water pump assembly2. Removal of thermostat assembly

1. Remove the heater hose.

2. Unscrew the bolts and remove the alternator.

Installation Notice


3. Unscrew the bolts and remove the alternator bracket.

Installation Notice

4. Unscrew the bolts and remove the water pump housing.

Installation Notice




Be careful not to damage the O-ring in coolant out-let pipe (cylinder head side).

Remove the gasket residues from the sealing sur-face and replace the gasket with new one.

NOTICE



AFFECTED VIN

24 06

RadiatorComponents of Radiator Module

Related Components (Assembly): Intercooler, Electric Fans, Condenser, RadiatorPreceding Works:1. Disconnection of negative battery cable2. Removal of front bumper assembly3. Discharge of refrigerant4. Draining of engine coolant

Removal Procedure

Intercooler Electric Fans

CondenserRadiator


AFFECTED VIN


2506

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Radiator and IntercoolerPreceding Works:1. Collect the refrigerant from A/C system.2. Remove the lower cover.3. Drain the engine coolant into the designated

container.

Removal and Installation1. Remove the air cleaner duct.

2. Disconnect the intercooler hoses.LH

RH

Store the refrigerant and engine coolant in a safeplace.

NOTICE

Tightening torque: 6 ~ 7 Nm




AFFECTED VIN

26 06

5. Unscrew the bolts and remove the radiator brackets.

3. Remove the inlet, outlet and return hoses.


4. Remove A/C hose and condenser pipe.

Inlet Hose Return Hose Outlet Hose

High Pressure Pipe:compressor side

Low Pressure Pipe:receiver drier side

Plug the openings of the pipes with sealing caps.NOTICE


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2706

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7. Pull out the fixing clips and remove the radiator.

6. Remove the transmission oil cooler pipes.

Installation Notice

Tightening torque 25 ~ 35 Nm

8. Remove the outlet pipe from the intercooler.

Tightening torque 6 ~ 7 Nm

Remove two bolts(10 mm)

Release the clamp




AFFECTED VIN

28 06

9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator.

Intercooler Assembly


AFFECTED VIN


2906

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10. Remove the T/M oil cooler pipes from the radiator.

11. Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

Radiator

Condenser



AFFECTED VIN

30 06

1. Turn the fan belt adjusting bolt (19 mm) counterclockwise.

Replacement of Fan BeltPreceding Work: Disconnect the negative battery cable.


AFFECTED VIN


3106

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Fan Belt Arrangement

2. Remove the fan belt.



AFFECTED VIN

32 06

1. Drain the coolant.2. Remove the hoses.


3. Unscrew the bolts and remove the coolant reservoir.

Installation Notice

Coolant Reservoir



AFFECTED VIN


3306

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3. Remove the drain plug and seal in the cylinder blockand drain the coolant.

4. Replace the seal with new one and install the drainplug.

Installation Notice

5. Install the drain plug in bottom of radiator.6. Add the coolant through the coolant reservoir.

7. Warm up the engine until the thermostat begins toopen and check if the coolant level is at FULL markon the reservoir. Add if necessary.

2. Loosen the drain plug in bottom of radiator and drainthe coolant.

1. Release the pressure from coolant reservoir by loos-ening one notch of coolant reservoir cap, and then re-move the cap.

Draining and Adding of Coolant


Scalding hot coolant and steam could be blown outunder pressure, which could cause serious injury.Never remove the coolant reservoir cap when thebefore the temperature goes down below 90C.

NOTICE

Collect the drained coolant with a proper container.NOTICE

Keep the coolant mixture ratio of 50:50 (water : anti-freezer).

Add the coolant until the water flows out throughthe overflow hose.

NOTICE

ActyonA0A06004.pdf

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