Repair Procedures

Removal

CAUTION:
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable.
2. Loosen the drain plug and drain the engine coolant.
3. Remove the air duct (A).
4. Remove the AFS connector (B) and air cleaner assembly (C).




5. Remove the radiator upper hose (A).




6. Remove the radiator lower hose (A).




7. Remove the front muffler (A).




8. Remove the exhaust manifold stays (A).




9. Remove the LH side coolant pipe and hose (A) and then remove the exhaust manifold heat protector (B).




10. Remove the RH side coolant pipe and hose (A) and then remove the exhaust manifold heat protector (B).




11. Remove the LH/RH exhaust manifold (A).










Installation

1. Install the LH/RH exhaust manifold (A).

Tightening torque :
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)








2. Install the RH side the exhaust manifold heat protector (B) and then install the coolant pipe and hose (A).

Tightening torque :
A : 19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
B : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




3. Install the LH side the exhaust manifold heat protector (B) and then install the coolant pipe and hose (A).

Tightening torque :
A : 19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
B : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




4. Install the front muffler (A).

Tightening torque :
39.2 - 58.8N.m (4.0 - 6.0kgf.m, 28.9 - 43.4lb-ft)




5. Install the exhaust manifold stays (A).

Tightening torque :
34.3 - 41.2N.m (3.5 - 4.2kgf.m, 25.3 - 30.4lb-ft)




6. Install the radiator lower hose(A).




7. Install the radiator upper hose(A).




8. Install the air cleaner assembly (C) and then connect the AFS connector (B).
9. Install the air duct (A).

Tightening torque :
Bolt : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
Clamp : 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)




10. Connect the battery negative cable.

NOTE:
- Refill engine coolant.
- Refill radiator and reservoir tank with engine coolant.
- 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 the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
- Clean the battery posts and cable terminals with sandpaper. Assemble and, then apply grease to prevent corrosion.