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16. REMOVE UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) Remove the 4 bolts and upper radiator support with
hood lock.
17. DISCONNECT NO. 1 RADIATOR HOSE
18. DISCONNECT NO. 2 RADIATOR HOSE
19. DISCONNECT NO. 2 WATER BY-PASS HOSE
Disconnect the by-pass hose from the radiator reservoir
and radiator.
20. REMOVE RADIATOR ASSEMBLY
(a) Separate the cooler condenser from the radiator.
HINT:
After detaching the condenser, make sure that all 4
fan shroud cushions are present.
(b) Remove the radiator with the 2 radiator support
lowers.
HINT:
After detaching the radiator, make sure that both
radiator support lowers are present.
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21. REMOVE FAN SHROUD WITH COOLING FAN
(a) Remove the 2 bolts and radiator from the fan
shroud.
INSTALLATION
1. INSTALL FAN SHROUD WITH COOLING FAN
(a) Install the fan shroud with cooling fan with the 2
bolts to the radiator.
Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
2. INSTALL RADIATOR ASSEMBLY
(a) Install the 4 fan shroud cushions to the cooler
condenser.
(b) Set the cooler condenser to the fan shroud.
(c) Install the 2 radiator support lower cushions to the
fan shroud.
(d) Install the radiator with cooler condenser and fan
shroud to the radiator support lower.
3. INSTALL UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) Install the upper radiator support with the 4 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
4. INSTALL NO. 2 FAN SHROUD
(a) Attach the 2 claws to install the No. 2 fan shroud
and install the 2 bolts.
Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
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5. INSTALL UPPER RADIATOR SUPPORT BRACKET
(a) Install the bracket with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
6. CONNECT HORN CONNECTOR
(a) Connect the 2 horn connectors.
7. CONNECT NO. 2 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator and
radiator reservoir.
HINT:
The direction of the hose clamp is indicated in the
illustration.
8. CONNECT NO. 2 RADIATOR HOSE
HINT:
The direction of the hose clamp is indicated in the
illustration.
9. CONNECT NO. 1 RADIATOR HOSE
HINT:
The direction of the hose clamp is indicated in the
illustration.
10. CONNECT COOLING FAN MOTOR HARNESS
(a) Attach the harness with the 5 clamps.
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(b) Connect the 2 fan motor connectors.
11. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the by-pass pipe with the 2 bolts to the upper
radiator support.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(b) Connect the No. 1 radiator hose to the pipe.
HINT:
The direction of the hose clamp is indicated in the
lustration.
12. CONNECT NO. 5 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator.
HINT:
The direction of the hose clamp is indicated in the
lustration.
13. CONNECT NO. 1 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator and
radiator reservoir.
HINT:
The direction of the hose clamp is indicated in the
illustration.
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14. CONNECT HOOD LOCK SWITCH CONNECTOR
15. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-10)
16. INSTALL BATTERY
17. INSTALL BATTERY CLAMP
(a) Attach the hook of the battery clamp to the battery
bracket.
(b) Temporarily tighten the nut and install the bolt.
(c) Adjust the battery clamp's position.
(d) Fully tighten the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
18. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
19. ADD ENGINE COOLANT (See page CO-6)
20. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
21. INSTALL RADIATOR SUPPORT OPENING COVER
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CO–62GR-FE COOLING – COOLING FAN SYSTEM
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ON-VEHICLE INSPECTION
HINT:
It is normal for the cooling fan to sometimes rotate when the
ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 94
C (201F))
(a) Turn the ignition switch ON with the A/C switch OFF.
(b) Check that the cooling fan stops.
If it does not, check the cooling fan relays and
engine coolant temperature sensor, and then check
for disconnection of the connector or wire breaks
between the cooling fan relay and engine coolant
temperature sensor.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) Check that the cooling fan rotates.
If it does not, check the fuses, cooling fan relays,
ECM and cooling fan, and then check for an open
circuit between the cooling fan relay and engine
coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor
connector.
2. CHECK COOLING FAN OPERATION AT HIGH
TEMPERATURES (Above 96
C (205F))
(a) Start the engine, and then raise the coolant
temperature to above 96
C (205F).
HINT:
Coolant temperature is the value detected by the
engine coolant temperature sensor on the cylinder
head.
(b) Check that the A/C switch is OFF.
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(c) Check that the cooling fan rotates.
If it does not, check the engine coolant temperature
sensor, cooling fan, harness or connector.
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2GR-FE COOLING – WATER PUMPCO–13
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6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, No. 2 idler pulley cover plate and
No. 2 idler pulley.
7. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner
assembly.
8. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump and water pump
gasket.
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump
assembly.
(b) Turn the pulley, and then check that the water pump
bearing moves smoothly without making a clicking
noise.
If it does not move smoothly, replace the water
pump assembly.
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new water pump gasket and the water
pump with the 16 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
9.1 N*m (93 kgf*cm, 81 in.*lbf) for bolt B
and C
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