REMOVAL AND INSTALLATION <4B1- PHEV>



Pre-removal Operation
  • Engine Coolant Draining (Refer to ).
  • Motor Coolant Draining (Refer to GROUP 14B - Motor Coolant Change ).
  • Power Drive Unit Removal (Refer to GROUP 54D - Inverter (Frontr) ) .
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Thermostat Removal (Refer to ).

Post-installation Operation
  • Thermostat Installation (Refer to ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ) .
  • Power Drive Unit Installation(Refer to GROUP 54D - Inverter (Front) ) .
  • Motor Coolant Refilling (Refer to 14B - Motor Coolant Change ).
  • Engine Coolant Refilling (Refer to ).





Removal steps


·
Brake booster vacuum hose connection (Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster <LHD>, <RHD>).


1.
Vacuum pipe assembly
<<A>>
>>C<<
2.
Radiator upper hose connection


3.
EGR valve pipe


4.
EGR pipe gasket


5.
Water outlet fitting


6.
Water outlet fitting gasket


·
Control wiring harness connection
<<B>>
>>B<<
7.
Engine coolant temperature sensor


8.
Throttle body water return hose


9.
Cooling water line hose


10.
Heater hose connection


11.
Harness bracket


12
Thermostat case


13.
Thermostat case gasket


·
Drive belt (Refer to GROUP 11G - Crankshaft Pulley .)


·
Water pump


14.
Water inlet pipe

>>A<<
15.
O-ring


16.
Cooling water line gasket

REMOVAL SERVICE POINTS



<<A>> HOSE CLIP/RADIATOR UPPER HOSE DISCONNECTION



1.Make mating marks on the radiator upper hose and the hose clip as shown to install them in the original position.

2.Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator upper hose.
note If there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.

<<B>> ENGINE COOLANT TEMPERATURE SENSOR REMOVAL



Use special tool water temp sensor wrench (MB992042) to remove the engine coolant temperature sensor.

INSTALLATION SERVICE POINTS



>>A<< O-RING INSTALLATION


caution Avoid adhesion of engine oil or grease to the O-ring.

Fit the O-ring in the water inlet pipe groove, wet the O-ring circumference or the pipe mounting area inner wall, and then insert the O-ring.

>>B<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION



1.Apply the specified sealant to the engine coolant temperature sensor thread.
Specified sealant: ThreeBond 1324N or equivalent
note Install the engine coolant temperature sensor immediately after applying sealant.

2.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Use special tool water temp sensor wrench (MB992042) to tighten the engine coolant temperature sensor to the specified torque.
Tightening torque: 30 ± 9 N·m

>>C<< RADIATOR UPPER HOSE CONNECTION



1.Insert radiator upper hose as far as the projection of the water outlet fitting.
2.Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.