REMOVAL AND INSTALLATION GENERAL -...
19
CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM - 2006.03 15 06 GENERAL SENSOR ASSY HOUSING INTAKE LUB COOLING FUEL CONTROL EXHAUST 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
Transcript of REMOVAL AND INSTALLATION GENERAL -...
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
1506
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16 06
Shroud and Cooling Fan/Clutch
Preceding Work:
1. Draining of coolant
2. 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.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
1706
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18 06
Preceding Works: 1. Draining of coolant
2. Removal of V-belt
3. Removal of shroud
4. Removal of cooling fan
1. Thermostat housing
2. Gasket ........................................................ Replace
3. Bolt ................................................................ 10 Nm
4. Belt pulley
5. Bolt ................................................................ 10 Nm
6. Water pump bearing housing
Water Pump - Assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
1906
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20 06
5. Unscrew the bolts and remove the water pumpassembly.
Installation Notice
6. Install in the reverse order of removal.
Tightening torque 10 Nm
• Replace the O-ring in oil dipstick with new one.
• Plug the oil dipstick hole with a cap not to get theforeign materials into the engine.
NOTICE
• Remove the gasket residues from the sealing sur-face and replace the gasket with new one.
NOTICE
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
2106
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
Preceding Works: 1. Draining of coolant
2. Removal of V-belt
3. Removal of cooling fan
4. Removal of intake duct (air cleaner to turbo charger)
1. Gasket ...................................................... Replace
2. Water pump housing
3. Bolt .............................................................. 10 Nm
4. Thermostat
5. Seal
6. Coolant hose
Thermostat
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
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.
Tightening torque 10 ± 1.0 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
2306
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
Water Pump Housing
Preceding Works:
1. Removal of water pump assembly
2. Removal of thermostat assembly
1. Remove the heater hose.
2. Unscrew the bolts and remove the alternator.
Installation Notice
Tightening torque 46 ± 4.6 Nm
3. Unscrew the bolts and remove the alternator bracket.
Installation Notice
4. Unscrew the bolts and remove the water pump housing.
Installation Notice
5. Install in the reverse order of removal.
Tightening torque 25 ± 2.5 Nm
Tightening torque 10 ± 1.0 Nm
• 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
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24 06
Radiator
Components of Radiator Module
Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
Preceding Works:
1. Disconnection of negative battery cable
2. Removal of front bumper assembly
3. Discharge of refrigerant
4. Draining of engine coolant
Removal Procedure
Intercooler Electric Fans
CondenserRadiator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
2506
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
Radiator and Intercooler
Preceding Works:
1. Collect the refrigerant from A/C system.
2. Remove the lower cover.
3. Drain the engine coolant into the designatedcontainer.
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
Tightening torque: 6 ~ 7 Nm
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26 06
5. Unscrew the bolts and remove the radiator brackets.
3. Remove the inlet, outlet and return hoses.
Tightening torque: 16 ~ 23 Nm
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
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
2706
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
Tightening torque: 6 ~ 7 Nm
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28 06
9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator.
Intercooler Assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
2906
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30 06
1. Turn the fan belt adjusting bolt (19 mm) counterclockwise.
Replacement of Fan Belt
Preceding Work: Disconnect the negative battery cable.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
3106
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
Fan Belt Arrangement
2. Remove the fan belt.
COOLING SYSTEMACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32 06
1. Drain the coolant.
2. Remove the hoses.
4. Install in the reverse order of removal.
3. Unscrew the bolts and remove the coolant reservoir.
Installation Notice
Coolant Reservoir
Tightening torque 7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEMACTYON SM - 2006.03
3306
GE
NE
RA
LS
EN
SO
RA
SS
YH
OU
SIN
GIN
TA
KE
LU
BC
OO
LIN
GF
UE
LC
ON
TR
OL
EX
HA
US
T
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
Tightening torque 30 Nm
• 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 90°C.
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
