RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0]

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Warning

•  Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.

•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.

•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION.)

2.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

3.  Remove the air cleaner, air hose and resonance chamber No.1 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

4.  Remove the front crossmember under cover. (See FRONT CROSSMEMBER UNDER COVER REMOVAL/INSTALLATION.)

5.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

6.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

7.  Remove the cooling fan component. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

11.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

12.  Inspect the ATF level. (See AUTOMATIC TRANSMISSION FLUID (ATF) LEVEL ADJUSTMENT [SJ6A-EL].)

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1	Upper radiator hose
2	Upper mount rubber bracket
3	Lower radiator hose
4	Oil hose (AT) (See Oil Hose Disconnecting Note.)
5	Lower mount rubber bracket (See Lower Mount Rubber Bracket Removal/Installation Note.)
6	Radiator (See Radiator Removal Note.) (See Radiator Installation Note.)
7	Center mount rubber bracket (See Center Mount Rubber Bracket Removal Note.)

Oil Hose Disconnecting Note

Note

•  ATF drains from the radiator and oil hoses when the oil hoses are disconnected.

1.  Place a container under the vehicle to collect drained ATF.

2.  Disconnect the oil hoses from the radiator.

3.  Secure the oil hoses using rope or equivalent with the hose ends facing upward so that ATF does not drain.

Lower Mount Rubber Bracket Removal/Installation Note

Caution

•  If the radiator is not supported when removing/installing the lower mount rubber brackets, the load applied to the condenser and cooler pipe could damage them. Remove/install the lower mount rubber brackets using two people, with one person supporting the radiator.

Radiator Removal Note

Caution

•  Always use two people when removing/installing the radiator, with one person supporting the radiator. Otherwise, the radiator could fall off and be damaged.

1.  Remove the bolts shown in the figure.

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Caution

•  When removing the radiator, the condenser bracket is caught on the urethane which damages the urethane. Always install new urethane after removing the radiator. (See Radiator Installation Note.)

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2.  Remove the radiator.

3.  If the radiator is to be reused, perform the following procedure:

(1)  Completely remove the urethane.

(2)  Clean the urethane installation surface.

Center Mount Rubber Bracket Removal Note

1.  Remove the front mudguard No.1. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

2.  Remove the front splash shield No.2. (See FRONT SPLASH SHIELD No.2 REMOVAL/INSTALLATION.)

3.  Remove the center mount rubber bracket.

Radiator Installation Note

Caution

•  When installing the radiator, the condenser bracket contacts the urethane which may peel and damage the urethane. Therefore, cut new urethane so that the condenser bracket can pass through the urethane cutting location.

1.  Cut new urethane at the location shown in the figure.

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2.  Install new urethane to the position (shaded area) shown in the figure.

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Note

•  There are scribed lines indicating the application areas of the urethane on the radiator.

•  The urethane can be twisted within the application area.

3.  Press the urethane with your fingers so that it does not peel off or float.

Caution

•  Always use two people when removing/installing the radiator, with one person supporting the radiator. Otherwise, the radiator could fall off and be damaged.

•  Install the radiator being careful not to damage the urethane. Otherwise, the condenser bracket may contact the urethane and damage it.

4.  Set the radiator to the installation position.

Note

•  Set the urethane aside using a long rod such as a flathead screwdriver, and then install the radiator.

•  Install the radiator so that the condenser bracket can pass through the cutting location of the urethane.

5.  Tighten the bolts shown in the figure.

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6.  Verify that the urethane is correctly installed.