WATER-COOLED CHARGE AIR COOLER RADIATOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5]

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Warning
•  If the engine cooling system cap or the water-cooled charge air cooler reserve tank cap is removed when the engine is hot, steam and boiling water may be injected, causing severe burns or severe injury. Perform the removal of the engine cooling system cap and water-cooled charge air cooler reserve tank cap when the engine is cool.
•  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 1.5].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

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

4.  Remove the engine coolant reserve tank. (See ENGINE COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

5.  Drain the engine coolant and water-cooled charge air cooler coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.5].) (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-D 1.5].)

6.  Remove the air cleaner and fresh-air duct component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

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

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Refill the engine coolant and water-cooled charge air cooler coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.5].) (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-D 1.5].)

11.  Inspect for engine coolant leakage and water-cooled charge air cooler coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-D 1.5].) (See WATER-COOLED CHARGE AIR COOLER COOLANT LEAKAGE INSPECTION [SKYACTIV-D 1.5].)

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1
Lower radiator hose
2
Upper mount rubber bracket
(See Upper Mount Rubber Bracket Removal Note.)
3
Upper mount rubber
4
Engine radiator component
(See Engine Radiator Component Removal Note.)
5
Water-cooled charge air cooler radiator
(See Water-cooled Charge Air Cooler 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.


Engine Radiator Component Removal Note

1.  Remove the wiring harness clips shown in the figure.

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2.  Detach the clip and set the cooler pipe aside.

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

4.  Disconnect the water hose from the water-cooled charge air cooler reserve tank.

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5.  Disconnect the water hose from the water pipe.

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6.  Remove the engine radiator component and the lower mount rubber from the shroud panel as a single unit.

Note
•  The engine radiator component and the lower mount rubber can be raised as a single unit by pressing the edges of the lower mount rubber from the holes on the underside of the shroud panel.
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7.  Move the engine radiator component and condenser to the engine side.

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8.  Remove the four bolts securing the condenser to the engine radiator.

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9.  Remove the engine radiator component from above the engine compartment.

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Water-cooled Charge Air Cooler Radiator Removal Note

1.  Disconnect the water-cooled charge air cooler coolant air-bleed hose from the engine radiator.

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2.  Remove the four bolts securing the water-cooled charge air cooler radiator to the engine radiator.

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3.  Remove the water-cooled charge air cooler radiator.

4.  When replacing the water-cooled charge air cooler radiator with a new one, remove the parts shown in the figure.

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