REMOVAL
| WARNING | Never remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine coolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way. |
Scheme 9
Scheme 10
- Remove the following parts: Engine under cover. Radiator core support covers (RH and LH): Refer to " «EXPLODED VIEW»(ref-404359-S39916522692011061100000) ". Air duct (inlet): Refer to " «EXPLODED VIEW»(ref-404359-S39916522692011061100000) ". Front grille: Refer to " «EXPLODED VIEW»(ref-404361-S30005658572011061100000) ". Horn: Refer to " «EXPLODED VIEW»(ref-404375-S15879714242011061100000) ". Hood lock: Refer to " «EXPLODED VIEW»(ref-404358-S36719507822011061100000) ".
- Drain engine coolant from radiator. Refer to " «DRAINING»(ref-404360-S40812041242011061100000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt.
- Disconnect reservoir tank hose from radiator pipe (upper).
- Disconnect CVT fluid cooler hoses from radiator. Install blind plug to avoid leakage of CVT fluid.
- Remove radiator cap adapter and each radiator hoses (upper) and radiator pipe (upper) assembly. CAUTION: Be careful not to allow engine coolant to contact drive belt.
- Disconnect radiator hose (lower) from radiator.
- Remove condenser. Refer to " «EXPLODED VIEW»(ref-404353-S32498221502011061100000) ". CAUTION: Be careful not to damage condenser core.
- Remove each radiator upper clips (2) by pulling the tabs (A) outside to release the lock (B) and then remove each mounting rubbers (upper) (1). CAUTION: Never pull the tabs outside excessively to prevent it from damping.
- Lift up and remove radiator (1) from front of radiator core support (2). CAUTION: Be careful not to damage or scratch on radiator core.
INSTALLATION
Note the following, and install in the reverse order of removal.
Radiator Upper Clip
Install each radiator upper clips on radiator core connection as follows
Scheme 11
- Install each mounting rubbers (upper) (1) on mounting pins (A) of radiator.
- Align each radiator upper clips (2) with radiator core connection (B), then insert each radiator upper clips straight into radiator core connections until a click is heard.
- After connecting each radiator upper clips, use the following method to check it is fully connected. Visually confirm that each radiator upper clips are connected to radiator core connections. Move each radiator upper clips and the radiator forward and backward to check they are securely connected.
- Remove the following parts. Engine under cover Air duct (inlet): Refer to " «EXPLODED VIEW»(ref-404359-S39916522692011061100000) ". Oil level gauge: Refer to " «EXPLODED VIEW»(ref-404359-S40627608342011061100000) ". Battery and battery tray: Refer to " «REMOVAL AND INSTALLATION»(ref-404351-S25053386812011061100000) ".
- Drain engine coolant from radiator. Refer to " «DRAINING»(ref-404360-S40812041242011061100000) ". CAUTION: Perform this step engine is cold. Never spill engine coolant on drive belt.
- Remove radiator cap adapter and each radiator hoses (upper) and radiator pipe (upper) assembly. Refer to " «EXPLODED VIEW»(ref-404360-S04692625142011061100000) ".
- Disconnect harness connector from fan motors (RH and LH), and move harness to aside.
- Disconnect harness connector from crash zone sensor, and move harness to aside. Refer to " «EXPLODED VIEW»(ref-404352-S10503199982011061100000) ".
- Remove battery tray bracket mounting bolts, and move battery tray bracket to aside.
- Remove cooling fan assembly. CAUTION: Be careful not to damage or scratch on radiator core.
Note the following, and install in the reverse order of removal.
| CAUTION | Only use genuine parts for cooling fan mounting bolt and observe the specified torque (to prevent radiator from being damaged). |
Note. Cooling fans are controlled by ECM. For details, refer to " SYSTEM DIAGRAM ".
Removal and Installation
| CAUTION | When removing water pump assembly, be careful not to get engine coolant on drive belt. Water pump cannot be disassembled and should be replaced as a unit. After installing water pump, connect hose and clamp securely, then check for leakage using the radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service tool). |
Scheme 12
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Scheme 16
- Remove the following parts. Air duct (inlet): Refer to " «EXPLODED VIEW»(ref-404359-S39916522692011061100000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-404359-S00720574382011061100000) ". Engine under cover Front road wheel and tire Splash guard (RH): Refer to " «FENDER PROTECTOR : EXPLODED VIEW»(ref-404361-S20992817702011061100000) ".
- Drain engine coolant from radiator. Refer to " «DRAINING»(ref-404360-S40812041242011061100000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt.
- Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-404359-S27933191582011061100000) ".
- Remove idler pulleys. Refer to " «EXPLODED VIEW»(ref-404359-S37852030232011061100000) ".
- Remove reservoir tank of radiator. Refer to " «EXPLODED VIEW»(ref-404360-S04692625142011061100000) ".
- Remove reservoir tank of power steering oil pump with piping connected, and move it to aside. Refer to " «EXPLODED VIEW»(ref-404364-S22003824302011061100000) ".
- Support oil pan (lower) bottom with transmission jack.
- Remove engine mounting insulator (RH), engine mounting bracket (RH) and upper torque rod. Refer to " «2WD : EXPLODED VIEW»(ref-404359-S04202061182011061100000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-404359-S37459983912011061100000) " (AWD models).
- Remove water drain plug (front) on water pump side of cylinder block to drain engine coolant from engine inside.
- Remove valve timing control cover (bank 1) and water pump cover from front timing chain case. Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
- Remove timing chain tensioner (primary) as follows: Remove lower mounting bolt (1). CAUTION: Be careful not to drop mounting bolt inside timing chain case. Loosen upper mounting bolt (2) slowly, and then turn chain tensioner (primary) (3) on the mounting bolt so that plunger (4) is fully expanded. NOTE: Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary). Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. Remove upper mounting bolt, and then remove timing chain tensioner (primary). CAUTION: Be careful not to drop mounting bolt inside timing chain case.
- Remove water pump as follows: Remove three water pump mounting bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum. Screw M8 bolts [pitch: 1.25 mm (0.0492 in) length: approximately 50 mm (1.97 in)] into water pumps upper and lower mounting bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump. CAUTION: Pull straight out while preventing vane from contacting socket in installation area. Remove water pump without causing sprocket to contact timing chain. Remove M8 bolts and O-rings from water pump. CAUTION: Never disassemble water pump.
Scheme 17
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Scheme 22
- Install new O-rings to water pump. Apply engine oil and engine coolant to O-rings as shown in the illustration. Locate O-ring with white paint mark to engine front side.
- Install water pump. CAUTION: Never allow cylinder block to nip O-rings when installing water pump. Check that timing chain and water pump sprocket are engaged. Insert water pump by tightening mounting bolts alternately and evenly.
- Install timing chain tensioner (primary) as follows: Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D). NOTE: Plunger stopper tab and lever (C) are synchronized. Push plunger into the inside of tensioner body. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B). The lever parts and the tab are synchronized. Therefore, the plunger will be secured under this condition. NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin. Install timing chain tensioner (primary). Remove dust and foreign material completely from backside of timing chain tensioner (primary) and from installation area of rear timing chain case. Remove stopper pin (A). Check again that timing chain and water pump sprocket are engaged.
- Install valve timing control cover (bank 1) and water pump cover as follows: Before installing, remove all traces of old liquid gasket from mating surface of water pump cover using scraper. Also remove traces of old liquid gasket from the mating surface of front timing chain case. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to mating surface of water pump cover (1). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-404349-S19299801482011061100000) ". CAUTION: Attaching should be done within 5 minutes after coating. Tighten mounting bolts.
- Install water drain plug (front) on water pump side of cylinder block. Apply liquid gasket to the thread of water drain plug (front). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-404349-S19299801482011061100000) ".
- Install in the reverse order of removal after this step. After starting engine, let idle for three minutes, then rev engine up to 3,000 RPM under no load to purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
Scheme 23
- Check for badly rusted or corroded water pump body assembly.
- Check for rough operation due to excessive end play.
- If anything is found, replace water pump.
Note the following, and install in the reverse order of removal.
- Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.
Scheme 24
- Check valve seating condition at ordinary room temperatures. It should seat tightly.
- Check valve operation. Thermostat (Standard) : Refer to " «THERMOSTAT»(ref-404360-S01883661212011061100000) ". If the malfunctioning condition, when valve seating at ordinary room temperature, or measured values are out of the standard, replace water inlet and thermostat assembly.
- Remove air duct (inlet), radiator core support covers (RH and LH), air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to " «EXPLODED VIEW»(ref-404359-S39916522692011061100000) ".
- Remove engine cover. Refer to " «EXPLODED VIEW»(ref-404359-S00720574382011061100000) ".
- Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the front of cylinder block. Refer to " «DRAINING»(ref-404360-S40812041242011061100000) " and " «SETTING»(ref-404359-S14526061492011061100000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt.
- Remove battery and battery tray. Refer to " «REMOVAL AND INSTALLATION»(ref-404351-S25053386812011061100000) ".
- Remove CVT fluid charging pipe and CVT fluid level gauge. Refer to " «EXPLODED VIEW»(ref-404371-S31635282342011061100000) ".
- Move CVT control cable aside. Refer to " «EXPLODED VIEW»(ref-404371-S35444019412011061100000) ".
- Remove vacuum tube (front) mounting bolt from water outlet. Refer to " «2WD : EXPLODED VIEW»(ref-404359-S04202061182011061100000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-404359-S37459983912011061100000) " (AWD models).
- Remove radiator hose (upper) from water outlet.
- Remove water hoses and heater hoses.
- Disconnect harness connectors, and move harness to aside.
- Remove engine coolant temperature sensor if necessary. CAUTION: Be careful not to damage engine coolant temperature sensor.
- Remove water outlet, heater pipe, water bypass pipe and water connector.
Note the following, and install in the reverse order of removal.
- Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
- When inserting water bypass pipe and heater pipe into water connector, apply neutral detergent to O-ring.