06 15

REMOVAL AND INSTALLATION

GENERAL
Coolant Hose (Inlet/Outlet)

ASSY
Preceding Work: Draining of coolant

1. Loosen the clamp and remove the coolant outlet hose

HOUSING
(engine to radiator).

EXHAUST I N T A K E
2. Disconnect the HFM sensor connector.
3. Remove the air intake duct from the air cleaner.

LUB
COOLING
FUEL
4. Loosen the clamp and remove the coolant inlet hose

CONTROL
(radiator to thermostat housing).

SENSOR

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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5. Lift up the vehicle and remove the skid plate.

6. Loosen the clamp and remove the lower inlet hose.

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.

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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5. Unscrew the center bolt and remove the cooling fan

GENERAL
clutch while holding the pulley with counter holder
(special tool).

Installation Notice

ASSY
Tightening torque 45 ± 4.5 Nm

HOUSING
EXHAUST I N T A K E
6. Remove the shroud.
7. Install in the reverse order of removal.

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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Water Pump - Assembly

Preceding Works: 1. Draining of coolant
2. Removal of V-belt
3. Removal of shroud
4. Removal of cooling fan

1. Thermostat housing 4. Belt pulley

2. Gasket ........................................................ Replace 5. Bolt ................................................................ 10 Nm
3. Bolt ................................................................ 10 Nm 6. Water pump bearing housing

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 06 19

1. Remove the V-belt while pressing down the auto

GENERAL
tensioner adjusting bolt.

ASSY
HOUSING
EXHAUST I N T A K E
2. Unscrew the bolts and remove the EGR pipe and
bracket.

Installation Notice
Tightening torque 23 ± 2.3 Nm

LUB
COOLING
3. Unscrew the bolts and remove the belt pulley while

FUEL
holding the belt pulley with a special tool.

Installation Notice

CONTROL
Tightening torque 10 Nm

SENSOR

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
20 06

NOTICE
• 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.

5. Unscrew the bolts and remove the water pump

assembly.

Installation Notice
Tightening torque 10 Nm

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

6. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 06 21

GENERAL
Thermostat
Preceding Works: 1. Draining of coolant
2. Removal of V-belt

ASSY
3. Removal of cooling fan
4. Removal of intake duct (air cleaner to turbo charger)

HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
1. Gasket ...................................................... Replace 4. Thermostat

SENSOR
2. Water pump housing 5. Seal
3. Bolt .............................................................. 10 Nm 6. Coolant hose

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
22 06

1. Unscrew the bolts and remove the thermostat housing.

Installation Notice
Tightening torque 10 ± 1.0 Nm

2. Remove the thermostat.

3. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 06 23

GENERAL
Water Pump Housing
Preceding Works:
1. Removal of water pump assembly

ASSY
2. Removal of thermostat assembly

1. Remove the heater hose.

HOUSING
EXHAUST I N T A K E
2. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque 46 ± 4.6 Nm

LUB
COOLING
3. Unscrew the bolts and remove the alternator bracket.

FUEL
Installation Notice
Tightening torque 25 ± 2.5 Nm

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

Installation Notice
Tightening torque 10 ± 1.0 Nm

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.

5. Install in the reverse order of removal.

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
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

Radiator Condenser

COOLING SYSTEM CHANGED BY

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AFFECTED VIN
 06 25

GENERAL
Radiator and Intercooler
Preceding Works:
1. Collect the refrigerant from A/C system.

ASSY
2. Remove the lower cover.
3. Drain the engine coolant into the designated
container.

HOUSING
NOTICE
• Store the refrigerant and engine coolant in a safe

EXHAUST I N T A K E
place.

Removal and Installation

1. Remove the air cleaner duct.

LUB
COOLING
FUEL
2. Disconnect the intercooler hoses.

CONTROL
LH

Tightening torque: 6 ~ 7 Nm SENSOR

RH

Tightening torque: 6 ~ 7 Nm

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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3. Remove the inlet, outlet and return hoses.

Inlet Hose Return Hose Outlet Hose

4. Remove A/C hose and condenser pipe.

High Pressure Pipe: Low Pressure Pipe:

compressor side receiver drier side

Tightening torque: 16 ~ 23 Nm

NOTICE
• Plug the openings of the pipes with sealing caps.

5. Unscrew the bolts and remove the radiator brackets.

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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6. Remove the transmission oil cooler pipes.

GENERAL
Installation Notice
Tightening torque 25 ~ 35 Nm

ASSY
HOUSING
EXHAUST I N T A K E
7. Pull out the fixing clips and remove the radiator.

LUB
COOLING
FUEL
8. Remove the outlet pipe from the intercooler.

Tightening torque 6 ~ 7 Nm

CONTROL
Release the clamp Remove two bolts
(10 mm)

SENSOR

Tightening torque: 6 ~ 7 Nm

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator.

Intercooler Assembly

COOLING SYSTEM CHANGED BY

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

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
11. Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

FUEL
Condenser

CONTROL
SENSOR

Radiator

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
30 06

Replacement of Fan Belt

Preceding Work: Disconnect the negative battery cable.

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

COOLING SYSTEM CHANGED BY

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AFFECTED VIN
 06 31

2. Remove the fan belt.

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
Fan Belt Arrangement

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY COOLING SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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Coolant Reservoir
1. Drain the coolant.
2. Remove the hoses.

3. Unscrew the bolts and remove the coolant reservoir.

Installation Notice
Tightening torque 7 Nm

4. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 06 33

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

ASSY
move the cap.

NOTICE

HOUSING
• Scalding hot coolant and steam could be blown out
under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90°C.

EXHAUST I N T A K E
2. Loosen the drain plug in bottom of radiator and drain
the coolant.

NOTICE
• Collect the drained coolant with a proper container.

LUB
COOLING
3. Remove the drain plug and seal in the cylinder block

FUEL
and drain the coolant.
4. Replace the seal with new one and install the drain
plug.

CONTROL
Installation Notice
Tightening torque 30 Nm

5. Install the drain plug in bottom of radiator. SENSOR

6. Add the coolant through the coolant reservoir.

NOTICE
• Keep the coolant mixture ratio of 50:50 (water : anti-
freezer).
• Add the coolant until the water flows out through
the overflow hose.

7. Warm up the engine until the thermostat begins to

open and check if the coolant level is at “FULL” mark
on the reservoir. Add if necessary.
CHANGED BY COOLING SYSTEM
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN