Engine Cooling System: Removal & Installation Hyundai Veloster I

Replacement And Air Bleeding

Note. When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off immediately.

Scheme 4

Scheme 5

1. Make sure the engine and radiator are cool to the touch.
2. Remove the radiator cap (A).
3. Remove the under cover.
4. Loosen the drain plug (A), and drain the coolant.
5. Tighten the radiator drain plug securely.
6. After draining engine coolant in the reservoir tank, clean the tank.
7. Fill the radiator with water through the radiator cap and tighten the cap. NOTE: To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.
8. Start the engine and allow to come to normal operating temperature. Wait for the cooling fans to turn on several times. Accelerate the engine to aid in purging trapped air. Shut engine off.
9. Wait until the engine is cool.
10. Repeat steps 1 to 8 until the drained water runs clear.
11. Fill fluid mixture with coolant and water (55~60%) (except for North America, Europe and China: 45~50%) slowly through the radiator cap. Push the upper/lower hoses of the radiator so as bleed air easily. NOTE: Use only genuine antifreeze/coolant. For best corrosion protection, the coolant concentration must be maintained year-round at 55% (except for North America, Europe and China: 45%) minimum. Coolant concentrations less than 55% (except for North America, Europe and China: 45%) may not provide sufficient protection against corrosion or freezing. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended. CAUTION: Do not mix different brands of antifreeze/coolants. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
12. Start the engine and run until coolant circulates. When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
13. Repeat step 11 until the cooling fan 3 ~ 5 times and bleed air sufficiently out of the cooling system.
14. Install the radiator cap and fill the reservoir tank to the "MAX" (or "F") line with coolant.
15. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
16. Stop the engine and wait coolant gets cool.
17. Repeat 10 to 15 until the coolant level doesn't fall any more, bleed air out of the cooling system. NOTE: It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, when recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant. Coolant capacity Turbo: MT : 6.1 L (1.61 U.S.gal., 6.44 U.S.qt., 5.36 lmp.qt.) AT : 5.9 L (1.55 U.S.gal., 6.23 U.S.qt., 5.18 lmp.qt.) Coolant capacity Non-Turbo: MT : 5.0L (1.32 U.S.gal., 5.28 U, S, qt., 4.40lmp.qt) AT : 5.2L (1.37 U.S.gal., 5.49 U, S, qt., 4.57lmp.qt)

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1. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
2. Disconnect the mounting clamp and then remove the heater hose (A).
3. Remove the heater hoses (A). NOTE: Install the heater hoses as shown in illustrations.
4. Install in the reverse order of removal.

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Scheme 10

1. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
2. Disconnect the radiator upper hose (A) and lower hose (B). NOTE: Install the radiator hoses as shown in illustrations.
3. Install in the reverse order of removal.

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Scheme 16

1. Disconnect the battery negative terminal.
2. Remove the air cleaner assembly. (Refer to " «AIR CLEANER»(ref-609292-S06516152692014041600000) ")
3. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. WARNING: Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
4. Disconnect the over flow hose (A) from the radiator.
5. Disconnect the radiator upper hose (A) and lower hose (B).
6. Disconnect the ATF cooler hoses. (Refer to «REPAIR PROCEDURES»(ref-609296-S17934812832014041600000) )
7. Remove the front bumper. (Refer to " «FRONT BUMPER»(ref-609306-S41736271712014041600000) ")
8. Remove the head lamp. (Refer to " «HEAD LAMPS»(ref-609307-S39565306942014041600000) ")
9. Remove the upper mounting bracket (A).
10. Disconnect the cooling fan controller connector (A).
11. Remove the air guard (A) and then disconnect the A/C condenser (B) from radiator.
12. Disconnect the radiator assembly from vehicle.
13. Remove the cooling fan & reservoir tank (A) from the radiator (B).
14. Install in the reverse order of removal.
15. Fill the radiator with coolant and check for leaks. NOTE: Bleed air from the cooling system. Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.) Turn off engine and let it cool down. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system. Put the radiator cap on tightly, then run engine again and check for leaks.

Scheme 17

1. Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester.
2. Apply a pressure of 93 ~ 123 kPa (0.95 ~ 1.25 kg/cm 2 , 14 ~ 19 psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Scheme 18

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install a pressure tester on it.
2. Apply a pressure of 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm 2 , 14 ~ 19 psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. If the pressure drops, check hoses, the radiator and the water pump for leakage. If there is no leakage, inspect the heater core, the cylinder block and the cylinder head.
5. Remove the tester and reinstall the radiator cap. NOTE: Check for engine oil in coolant and/or coolant in engine oil.

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1. Disconnect the battery negative terminal.
2. Remove the air cleaner assembly. (Refer to " «AIR CLEANER»(ref-609292-S06516152692014041600000) ")
3. Disconnect the over flow hose (A) from the radiator.
4. Disconnect the ATF cooler hose from cooling fan.
5. Remove the front bumper. (Refer to " «FRONT BUMPER»(ref-609306-S41736271712014041600000) ")
6. Remove the head lamp. (Refer to " «HEAD LAMPS»(ref-609307-S39565306942014041600000) ")
7. Remove the radiator upper bracket (A).
8. Disconnect the cooling fan controller connector (A).
9. Remove the filler neck assembly bolts (A).
10. Remove the cooling fan assembly (B) from radiator (A). Tightening torque: 4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.7 lb-ft)
11. Install in the reverse order of removal.

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1. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
2. Disconnect the battery negative terminal.
3. Remove the air cleaner assembly. (Refer to " «AIR CLEANER»(ref-609292-S06516152692014041600000) ")
4. Disconnect the water temperature sensor connector (A).
5. Disconnect the radiator upper hose (B).
6. Remove the heater hose (C).
7. Disconnect the water hose (D).
8. Remove the water temperature control assembly (B). Tightening torque: 9.8 ~ 11.7 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
9. Install in the reverse order of removal. CAUTION: Clean the surface of the water temperature control assembly before installing.

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1. Remove the water temperature control assembly. (Refer to " «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-609294-S42795037032014041600000) ")
2. Remove the water pipe (A). Tightening torque M6 bolt and nuts: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) M8 bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
3. Install in the reverse order of removal.

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1. Loosen the drain plug (A), and drain the engine coolant. Remove the radiator cap to drain with speed. WARNING: System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
2. Remove the drive belt. (Refer to " «DRIVE BELT»(ref-609300-S14058388782014041600000) ")
3. Remove the water pump pulley (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
4. Remove the water pump (A).

Removal

Note. Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.

Scheme 35

1. Drain engine coolant so that its level would be under the thermostat height.
2. Remove the radiator lower hose. (Refer to " «RADIATOR HOSE»(ref-609294-S27516986072014041600000) ")
3. Remove the water inlet fitting (A) and thermostat (B).

Scheme 36

1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature. Valve opening temperature: 82±1.5° C (179.6±2.7° F) Full opening temperature: 95° C (203° F) If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift. Valve lift: 8 mm (0.3 in) or more at 95° C (203° F) If the valve lift is not as specified, replace the thermostat.

Scheme 37

1. Place the thermostat in the block. Install the thermostat (B) with the jiggle valve upward.
2. Install the water inlet fitting (A). Tightening torque: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.