CO-62
< ON-VEHICLE REPAIR >[K9K]
RADIATOR
ON-VEHICLE REPAIR
RADIATOR
Exploded ViewINFOID:0000000001381591
Removal and InstallationINFOID:0000000001381592
WARNING:
Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high
pressure coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quar-
ter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.
REMOVAL
1. Remove engine undercover using power tool.
2. Drain engine coolant. Refer to CO-58, "
Draining".
CAUTION:
Perform when engine is cold.
3. Remove engine cover.
4. Remove air duct (inlet). Refer to EM-269, "
Exploded View".
5. Remove reservoir tank hoses and reservoir tank.
1. Mounting rubber (upper) 2. Radiator 3. Mounting rubber (lower)
4. Clamp 5. Radiator hose (lower) 6. Cooling fan assembly
7. Cooling fan control module 8. Reservoir tank hose (lower) 9. Reservoir tank
10. Reservoir tank hose (upper) 11. Radiator hose (upper) 12. Clamp
A. To water inlet B. To water outlet
ALBIA0423GB
CO-64
< ON-VEHICLE REPAIR >[K9K]
COOLING FAN
COOLING FAN
Exploded ViewINFOID:0000000001381594
Removal and InstallationINFOID:0000000001381595
REMOVAL
1. Remove engine undercover using power tool.
2. Drain engine coolant. Refer to CO-58, "
Draining".
3. Remove air duct (inlet). Refer to EM-269, "
Exploded View".
4. Disconnect reservoir tank hoses and remove reservoir tank.
5. Remove radiator hose (upper). Refer to CO-62, "
Exploded View".
6. Disconnect harness connector for cooling fan control module and fan motor, and move harness aside.
7. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Only use genuine parts for fan shroud bolt and observe the specified torque (to prevent radiator from
being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to CO-52, "
EngineCoolingSystem".
1. Fan shroud 2. Cooling fan control module 3. Fan motor
4. Cooling fan
A. Reverse screw
: Vehicle front
ALBIA0424GB
CO-68
< ON-VEHICLE REPAIR >[K9K]
WATER OUTLET AND THERMOSTAT ASSEMBLY
WATER OUTLET AND THERMOSTAT ASSEMBLY
Exploded ViewINFOID:0000000001381601
Removal and InstallationINFOID:0000000001381602
REMOVAL
1. Remove battery.
2. Remove engine undercover using power tool.
3. Drain engine coolant. Refer to CO-58, "
Draining".
CAUTION:
Perform when engine is cold.
4. Remove engine cover.
5. Remove air cleaner and air duct assembly. Refer to EM-269, "
Removal and Installation".
6. Remove rear engine slinger. Refer to EM-314, "
Exploded View".
7. Remove vacuum hose.
8. Remove vacuum pump. Refer to EM-280, "
Removal and Installation".
9. Remove radiator upper hose. Refer to CO-62, "
Exploded View".
10. Remove heater hose.
11. Disconnect reservoir tank hose.
12. Remove water outlet.
INSTALLATION
Installation is in the reverse order of removal.
InspectionINFOID:0000000001381603
INSPECTION AFTER REMOVAL
1. O-ring 2. EGR cooler cover 3. Clamp
4. Water pipe 5. Heater hose 6. Clamp
7. Engine coolant temperature sensor 8. O-ring 9. Lock plate
10. Clamp 11. Gasket 12. Water outlet and thermostat assembly
13. Air relief plug
A. To EGR volume control valve housing B. To radiator hose (upper) C. To heater core
E1BIA0027GB
DLK-204
< SYMPTOM DIAGNOSIS >[WITH I-KEY, WITHOUT SUPER LOCK]
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Inspection ProcedureINFOID:0000000001396664
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
RADIATOR CORE SUPPORT
DLK-219
< REMOVAL AND INSTALLATION >[WITH I-KEY, WITHOUT SUPER LOCK]
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
RADIATOR CORE SUPPORT
Removal and InstallationINFOID:0000000001315835
REMOVAL
Radiator Core Support Upper
1. Remove the air duct. Refer to EM-27, "Removal and Installation" (HR16DE), EM-154, "Removal and
Installation" (MR18DE), or EM-269, "Removal and Installation" (K9K).
2. Remove the headlamp (LH/RH). Refer to EXL-84, "
Removal and Installation" .
3. Remove the hood lock assembly, and remove hood lock cable. Refer to DLK-215
.
4. Remove the air guide and hood lock cable clip.
5. Remove the washer tank inlet. Refer to WW-64, "
Removal and Installation" .
6. Remove the radiator core support upper.
Radiator Core Support Lower
1. Remove the air duct. Refer to EM-27, "Removal and Installation" (HR16DE), EM-154, "Removal and
Installation" (MR18DE), or EM-269, "Removal and Installation" (K9K).
2. Remove the front bumper. Refer to EXT-13, "
Removal and Installation" .
3. Remove the headlamp (LH/RH). Refer to EXL-84, "
Removal and Installation" .
4. Remove the hood lock assembly, and remove hood lock cable. Refer to DLK-215
.
5. Remove the air guide and hood lock cable mounting clip.
6. Remove the front bumper reinforcement. Refer to EXT-13, "
Removal and Installation".
7. Remove the radiator core lower stay.
8. Remove the undercover.
PIIB6515E
1. Radiator core support upper 2. Radiator core support lower 3. Radiator core support lower stay
4. Radiator core support side stay 5. Air guide
24.5 N·m (2.5 kg-m, 18 ft-lb)
SQUEAK AND RATTLE TROUBLE DIAGNOSES
DLK-433
< SYMPTOM DIAGNOSIS >[WITH I-KEY & SUPER LOCK]
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Inspection ProcedureINFOID:0000000001396892
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
DLK-448
< REMOVAL AND INSTALLATION >[WITH I-KEY & SUPER LOCK]
RADIATOR CORE SUPPORT
RADIATOR CORE SUPPORT
Removal and InstallationINFOID:0000000001732021
REMOVAL
Radiator Core Support Upper
1. Remove the air duct. Refer to EM-27, "Removal and Installation" (HR16DE), EM-154, "Removal and
Installation" (MR18DE), or EM-269, "Removal and Installation" (K9K).
2. Remove the headlamp (LH/RH). Refer to EXL-84, "
Removal and Installation" .
3. Remove the hood lock assembly, and remove hood lock cable. Refer to DLK-444
.
4. Remove the air guide and hood lock cable clip.
5. Remove the washer tank inlet. Refer to WW-64, "
Removal and Installation" .
6. Remove the radiator core support upper.
Radiator Core Support Lower
1. Remove the air duct. Refer to EM-27, "Removal and Installation" (HR16DE), EM-154, "Removal and
Installation" (MR18DE), or EM-269, "Removal and Installation" (K9K).
2. Remove the front bumper. Refer to EXT-13, "
Removal and Installation" .
3. Remove the headlamp (LH/RH). Refer to EXL-84, "
Removal and Installation" .
4. Remove the hood lock assembly, and remove hood lock cable. Refer to DLK-444
.
5. Remove the air guide and hood lock cable mounting clip.
6. Remove the front bumper reinforcement. Refer to EXT-13, "
Removal and Installation".
7. Remove the radiator core lower stay.
8. Remove the undercover.
PIIB6515E
1. Radiator core support upper 2. Radiator core support lower 3. Radiator core support lower stay
4. Radiator core support side stay 5. Air guide
24.5 N·m (2.5 kg-m, 18 ft-lb)
SQUEAK AND RATTLE TROUBLE DIAGNOSES
DLK-575
< SYMPTOM DIAGNOSIS >[WITHOUT I-KEY & SUPER LOCK]
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Inspection ProcedureINFOID:0000000001397115
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking