RADIATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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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 [SKYACTIV-D 2.2].)

2.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

4.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the air cleaner and fresh air duct component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Remove the charge air cooler inlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

8.  Disconnect the service plug. (With i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

9.  Disconnect the generator terminal B cable and set the wiring harness aside. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2 (WITH i-ELOOP)].) (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2 (WITHOUT i-ELOOP)].)

10.  Remove the cooling fan component. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

12.  Remove the turbocharger air outlet pipe component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove the charge air cooler outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

14.  Remove in the order indicated in the table.

15.  Install in the reverse order of removal.

16.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

17.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-D 2.2].)

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1
Upper radiator hose
2
Lower radiator hose
3
Upper mount rubber bracket
(See Upper Mount Rubber Bracket Removal Note.)
4
Upper mount rubber
5
Radiator
(See Radiator Removal Note.)


Upper Mount Rubber Bracket Removal Note

Caution
•  To prevent damage to the upper mount rubber bracket tab, do not apply excessive force.

1.  While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the figure, pull out the upper mount rubber bracket toward the vehicle rear.

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2.  Remove the upper mount rubber bracket.


Radiator Removal Note

1.  To prevent damage to the radiator core, protect it by covering the radiator surface with cardboard.

2.  Lift the radiator and remove it from the radiator installation holes on the shroud panel.

3.  Move the radiator and condenser to the engine side.

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4.  Remove the bolts which secure the condenser to the radiator.

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5.  Remove the radiator from above the engine compartment.