Repair Procedures

Removal

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.

1. Disconnect the negative terminal from the battery.
2. Remove the engine cover (A).




3. Loosen the drain plug and drain the engine coolant.
4. Remove the air duct (A), and the air cleaner assembly (B).




5. Disconnect the radiator upper hose (A) and lower hose (B).




6. Turn the tensioner (B) clockwise and loosen, then remove the drive belt (A).




7. Remove the water pump pulley (A).




8. Remove the water pump (A).





Water pipe
1. Remove the intake manifold module.
2. Remove the water outlet pipe (A) and the water inlet pipe (B).





NOTE:
Remove the drain plug (A) and drain the engine coolant.





Installation

1. Install the water pump (A).

Tightening torque :
19.6 - 24.5N.m (2.0 - 2.5kgf.m, 14.5 - 18.1lb-ft)




2. Install the water pump pulley (A).

Tightening torque :
18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)

NOTE:
Tighten every bolt diagonally.




3. Turn the tensioner (B) clockwise and loosen, then install the drive belt (A).




4. Connect the radiator upper hose (A) and lower hose (B).




5. Install the air cleaner assembly (B) and air duct (A).

Tightening torque
Hose clamp bolt:
2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)
Air cleaner assembly bolts:
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




6. Install the engine cover (A).




7. Connect the battery negative terminal.

Tightening torque : 4.0 - 6.0N.m (0.4 - 0.6kgf.m, 3.0 - 4.4lb-ft)

8. Fill the radiator with coolant and check for leaks.

Water pipe
1. Install the O-ring to the water pipes.

NOTE:
- Use new O-rings when reassembling.
- Never apply sort of oil on O-ring and O-ring groove of pipe end.
- O-ring must be free from scratching damage.

2. Install the water outlet pipe (A) and the water inlet pipe (B).

Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

NOTE:
- Make clean the contact face before assembly.
- Insert pipe after to be wetting O-ring or inside of attaching hole by water or antifreeze.





NOTE:
Install the drain plug (A).

Tightening torque :
96.1 - 100.0N.m(9.8 - 10.2kgf.m,70.9 - 73.8lb-ft)




3. Install the intake manifold module.