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06

15
GENERAL

REMOVAL AND INSTALLATION

ASSY

Coolant Hose (Inlet/Outlet)


Preceding Work: Draining of coolant

EXHAUST I N T A K E

HOUSING

1. Loosen the clamp and remove the coolant outlet hose


(engine to radiator).

2. Disconnect the HFM sensor connector.

FUEL

COOLING

LUB

3. Remove the air intake duct from the air cleaner.

SENSOR

CONTROL

4. Loosen the clamp and remove the coolant inlet hose


(radiator to thermostat housing).

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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06

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
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

06

17
GENERAL

5. Unscrew the center bolt and remove the cooling fan


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

45 4.5 Nm

EXHAUST I N T A K E

HOUSING

Tightening torque

ASSY

Installation Notice

6. Remove the shroud.

SENSOR

CONTROL

FUEL

COOLING

LUB

7. Install in the reverse order of removal.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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06

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
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

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19

EXHAUST I N T A K E

HOUSING

ASSY

GENERAL

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


tensioner adjusting bolt.

2. Unscrew the bolts and remove the EGR pipe and


bracket.
Installation Notice
23 2.3 Nm

COOLING

LUB

Tightening torque

FUEL

3. Unscrew the bolts and remove the belt pulley while


holding the belt pulley with a special tool.

10 Nm

SENSOR

Tightening torque

CONTROL

Installation Notice

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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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 surface and replace the gasket with new one.

6. Install in the reverse order of removal.

COOLING SYSTEM
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

21
GENERAL

06

Thermostat
Preceding Works: 1. Draining of coolant

ASSY

2. Removal of V-belt
3. Removal of cooling fan

1. Gasket ...................................................... Replace

4. Thermostat

2. Water pump housing

5. Seal

3. Bolt .............................................................. 10 Nm

6. Coolant hose

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

SENSOR

CONTROL

FUEL

COOLING

LUB

EXHAUST I N T A K E

HOUSING

4. Removal of intake duct (air cleaner to turbo charger)

COOLING SYSTEM
ACTYON SM - 2006.03

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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
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

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GENERAL

06

Water Pump Housing


Preceding Works:

ASSY

1. Removal of water pump assembly


2. Removal of thermostat assembly

EXHAUST I N T A K E

HOUSING

1. Remove the heater hose.

2. Unscrew the bolts and remove the alternator.


Installation Notice
46 4.6 Nm

COOLING

LUB

Tightening torque

FUEL

3. Unscrew the bolts and remove the alternator bracket.


Installation Notice

CONTROL

25 2.5 Nm

SENSOR

Tightening torque

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


Installation Notice
Tightening torque

10 1.0 Nm

NOTICE
Be careful not to damage the O-ring in coolant outlet pipe (cylinder head side).
Remove the gasket residues from the sealing surface and replace the gasket with new one.

5. Install in the reverse order of removal.


CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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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

Radiator

COOLING SYSTEM
ACTYON SM - 2006.03

Electric Fans

Condenser

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AFFECTED VIN

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GENERAL

06

Radiator and Intercooler


Preceding Works:

ASSY

1. Collect the refrigerant from A/C system.


2. Remove the lower cover.

HOUSING

3. Drain the engine coolant into the designated


container.
NOTICE

EXHAUST I N T A K E

Store the refrigerant and engine coolant in a safe


place.

Removal and Installation

LH

SENSOR

2. Disconnect the intercooler hoses.

CONTROL

FUEL

COOLING

LUB

1. Remove the air cleaner duct.

Tightening torque: 6 ~ 7 Nm
RH

Tightening torque: 6 ~ 7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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06

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:
compressor side

Low Pressure Pipe:


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
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

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GENERAL

6. Remove the transmission oil cooler pipes.


Installation Notice
25 ~ 35 Nm

EXHAUST I N T A K E

HOUSING

ASSY

Tightening torque

FUEL

COOLING

LUB

7. Pull out the fixing clips and remove the radiator.

8. Remove the outlet pipe from the intercooler.

Release the clamp

Remove two bolts


(10 mm)

Tightening torque: 6 ~ 7 Nm

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

CONTROL

6 ~ 7 Nm

SENSOR

Tightening torque

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06

9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator.

Intercooler Assembly

COOLING SYSTEM
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

06

29

COOLING

LUB

EXHAUST I N T A K E

HOUSING

ASSY

GENERAL

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

FUEL

11. Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

SENSOR

CONTROL

Condenser

Radiator

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EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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06

Replacement of Fan Belt


Preceding Work: Disconnect the negative battery cable.

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

COOLING SYSTEM
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

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31

EXHAUST I N T A K E

HOUSING

ASSY

GENERAL

2. Remove the fan belt.

SENSOR

CONTROL

FUEL

COOLING

LUB

Fan Belt Arrangement

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03

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06

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
ACTYON SM - 2006.03

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

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GENERAL

06

Draining and Adding of Coolant

ASSY

1. Release the pressure from coolant reservoir by loosening one notch of coolant reservoir cap, and then remove the cap.

HOUSING

NOTICE

EXHAUST I N T A K E

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 90C.

2. Loosen the drain plug in bottom of radiator and drain


the coolant.
NOTICE

COOLING

LUB

Collect the drained coolant with a proper container.

FUEL

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


and drain the coolant.

CONTROL

4. Replace the seal with new one and install the drain
plug.
Installation Notice
30 Nm

SENSOR

Tightening torque

5. Install the drain plug in bottom of radiator.


6. Add the coolant through the coolant reservoir.
NOTICE
Keep the coolant mixture ratio of 50:50 (water : antifreezer).
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
EFFECTIVE DATE
AFFECTED VIN

COOLING SYSTEM
ACTYON SM - 2006.03