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B ENGINE

CO
SECTION
ENGINE COOLING SYSTEM C

E
CONTENTS
QG18DE QR25DE F

PRECAUTIONS ......................................................... 3 . PRECAUTIONS ....................................................... 21 .
Liquid Gasket Application Procedure ...................... 3 . Precautions For Liquid Gasket .............................. 21 .
G
PREPARATION .......................................................... 4. REMOVAL OF LIQUID GASKET ........................ 21 .
Special Service Tools .............................................. 4 . LIQUID GASKET APPLICATION PROCEDURE 21 ...
OVERHEATING CAUSE ANALYSIS ......................... 5 . PREPARATION ........................................................ 22.
Troubleshooting Chart ............................................. 5 . Special Service Tools ............................................ 22 . H
COOLING SYSTEM ................................................... 7 . OVERHEATING CAUSE ANALYSIS ....................... 23 .
Cooling Circuit ......................................................... 7
. Troubleshooting Chart ........................................... 23 .
ENGINE COOLANT ................................................... 8 . COOLING SYSTEM ................................................. 25 . I
System Check ......................................................... 8
. Cooling Circuit ....................................................... 25
.
CHECKING COOLING SYSTEM HOSES ........... 8 . ENGINE COOLANT ................................................. 26 .
CHECKING COOLING SYSTEM FOR LEAKS ..... 8 System Check ....................................................... 26
. J
CHECKING RADIATOR ....................................... 8 . CHECKING COOLING SYSTEM HOSES .......... 26 .
CHECKING RADIATOR CAP ............................... 9 . CHECKING RESERVOIR LEVEL ...................... 26 .
Refilling Engine Coolant .......................................... 9 . CHECKING COOLING SYSTEM FOR LEAKS ... 26
WATER PUMP ......................................................... 10 . CHECKING RADIATOR ..................................... 26 . K
Removal and Installation ....................................... 10 . CHECKING RADIATOR CAP ............................. 27 .
Inspection ...............................................................11
. Refilling Engine Coolant ........................................ 27 .
THERMOSTAT AND THERMOSTAT HOUSING ..... 12 . WATER PUMP ......................................................... 28. L
Removal and Installation ....................................... 12 . Removal and Installation ....................................... 28 .
Inspection .............................................................. 13
. REMOVAL .......................................................... 28
.
RADIATOR ............................................................... 14
. INSPECTION AFTER REMOVAL ...................... 29 . M
Removal and Installation ....................................... 14 . INSTALLATION .................................................. 29 .
REMOVAL .......................................................... 14. INSPECTION AFTER INSTALLATION ............... 29 .
INSTALLATION .................................................. 14 . THERMOSTAT AND THERMOSTAT HOUSING ..... 30 .
Disassembly and Assembly .................................. 15 . Removal and Installation ....................................... 30 .
PREPARATION ................................................. 15 . REMOVAL .......................................................... 30
.
DISASSEMBLY .................................................. 15 . INSPECTION AFTER REMOVAL ...................... 31 .
ASSEMBLY ........................................................ 16 . INSTALLATION .................................................. 31 .
Inspection .............................................................. 18
. RADIATOR ............................................................... 32
.
COOLING FAN ........................................................ 19 . Removal and Installation ....................................... 32 .
Disassembly and Assembly .................................. 19 . REMOVAL .......................................................... 32
.
DISASSEMBLY .................................................. 19 . INSTALLATION .................................................. 32 .
ASSEMBLY ........................................................ 19 . Disassembly and Assembly ................................... 33 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 20 . PREPARATION .................................................. 33 .
Capacity ................................................................ 20
. DISASSEMBLY .................................................. 33 .
Thermostat ............................................................ 20
. ASSEMBLY ........................................................ 34.
Radiator ................................................................. 20
. Inspection .............................................................. 36
.

CO-1
COOLING FAN ......................................................... 37
. SERVICE DATA AND SPECIFICATIONS (SDS) .....38 .
Disassembly and Assembly ................................... 37 . Capacity .................................................................38
.
DISASSEMBLY .................................................. 37
. Thermostat .............................................................38
.
ASSEMBLY ........................................................ 37
. Water Control Valve ...............................................38 .
Radiator .................................................................38
.

CO-2
PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Liquid Gasket Application Procedure EBS006BP

1. Use a scraper to remove all traces of old RTV Silicone Sealant from mating surfaces and grooves. Also,
completely clean any oil from these areas. CO
2. Apply a continuous bead of Genuine RTV Silicone Sealant or
equivalent to the mating surfaces. Refer to GI-44, "RECOM-
MENDED CHEMICAL PRODUCTS AND SEALANTS" .
C
q For oil pan, be sure RTV Silicone Sealant diameter is 3.5 to
4.5 mm (0.138 to 0.177 in).
q For areas except oil pan, be sure RTV Silicone Sealant diam-
D
eter is 2.0 to 3.0 mm (0.079 to 0.118 in).

E
SEM164F

3. Apply RTV Silicone Sealant around the inner side of bolt holes F
(unless otherwise specified).

AEM080 I

4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling the engine with the recommended oil and coolant. Refer to MA-13, J
"RECOMMENDED FLUIDS AND LUBRICANTS" .

CO-3
PREPARATION
[QG18DE]
PREPARATION PFP:00002

Special Service Tools EBS006BQ

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Description
Tool name
EG17650301 Adapting radiator cap tester to radiator filler
(J33984-A) neck
Radiator cap tester adapter a: 28 (1.10) via.
b: 31.4 (1.236) via.
c: 41.3 (1.626) via.
Unit: mm (in)

NT564

KV99103510 Installing radiator upper and lower tanks
( -- )
Radiator plate pliers A

S-NT224

KV99103520 Removing radiator upper and lower tanks
( -- )
Radiator plate pliers B

S-NT225

CO-4
OVERHEATING CAUSE ANALYSIS
[QG18DE]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS006BR

Symptom Check items
Water pump malfunction Worn or loose drive belt CO
Thermostat stuck closed Coolant circulation
Dust contamination or
C
Poor heat transfer Damaged fins paper clogging --
Mechanical damage
Clogged radiator cooling Excess foreign material D
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
E
High resistance to fan rota- Engine cooling fans --
Reduced air flow tion
Damaged fan blades
F
Damaged radiator shroud Radiator shroud --
Improper coolant mixture
Cooling sys- --
Engine runs hot ratio Coolant quality, viscosity G
tem parts
malfunction Poor coolant quality --
Loose clamp
Cooling hose H
Cracked hose
Water pump Poor sealing
Loose
Radiator cap I
Poor sealing
Coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting J
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank K
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system L
rioration

CO-5
OVERHEATING CAUSE ANALYSIS
[QG18DE]
Symptom Check items
High engine RPM under no
load
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
Over heating engine Overload on engine
Powertrain system mal-
function
Installed improper size
Except cool- --
wheels and tires
ing system
parts mal- Dragging brakes
function
Improper ignition timing
Blocked bumper --
Installed car brassiere
Blocked radiator grille Mud, debris or paper clog-
Blocked or restricted air ging --
flow
Blocked radiator Dirty radiator
Blocked condenser Dirty condenser
Blockage in front of radiator Installed large fog lamp

CO-6
COOLING SYSTEM
[QG18DE]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS006BS

SEM939F

CO-7
ENGINE COOLANT
[QG18DE]
ENGINE COOLANT PFP:KQ100

System Check EBS006BT

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
fluid escaping from the radiator.
Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pres-
sure to escape. Carefully remove the cap by pushing down and turning it all the way.
CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
q Improper attachment
q Leaks
q Cracks
q Damage
q Loose connections
q Chafing
q Deterioration
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure : 157 kPa (1.6 kg/cm2 , 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC756A

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
q Be careful not to bend or damage the radiator fins.
q When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing when clear water flows off of the radiator.
4. Blow air into the back side of radiator core vertically downward.
q Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 300 mm (11.8
in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CO-8
ENGINE COOLANT
[QG18DE]
CHECKING RADIATOR CAP
q To check radiator cap, apply pressure to cap with a tester. A
Radiator cap relief pressure
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi) CO
Limit 2
: 59 - 98 kPa (0.6 - 1.0 kg/cm , 9 - 14 psi)

SLC755A
D

q Pull the negative pressure valve to open it.
Check that it closes completely when released. E

SMA967B

Refilling Engine Coolant EBS006BU
H

Changing the engine coolant is part of the required maintenance of the engine. Refer to MA-16, "REFILLING
ENGINE COOLANT" .
I

CO-9
WATER PUMP
[QG18DE]
WATER PUMP PFP:21020

Removal and Installation EBS006BV

WLC017

CAUTION:
q When removing water pump assembly, be careful not to get coolant on drive belt.
q Water pump cannot be disassembled and should be replaced as a unit.
q After installing water pump, check for leaks using radiator cap tester. Refer to CO-8, "CHECKING
COOLING SYSTEM FOR LEAKS" .
1. Drain engine coolant.
Refer to MA-15, "DRAINING ENGINE COOLANT" .

WLC007

SEM869F

2. Remove front RH wheel.
3. Remove engine side cover.
4. Remove drive belts and idler pulley.
5. Loosen water pump pulley bolts.
6. Remove water pump pulley.

CO-10
WATER PUMP
[QG18DE]
7. Remove the water pump bolts.
8. Remove the water pump. A
q Remove RTV Silicone Sealant from water pump and mating
surface of cylinder block using a scraper.
9. Installation is in the reverse order of removal. CO
q When applying RTV Silicone Sealant to mating surface of
water pump, use Genuine RTV Silicone Sealant or equivalent.
Refer to GI-44, "RECOMMENDED CHEMICAL PRODUCTS C
AND SEALANTS" .
q When filling radiator with coolant, refer to MA-16, "REFILLING SEM859F
ENGINE COOLANT" . D
q When installing drive belts, refer to MA-15, "Checking Drive Belts" .

Inspection EBS006BW
E
1. Rotate water pump shaft, replace the water pump as necessary.
q Check body assembly and vane for rust or corrosion.
q Check for rough operation due to excessive end play. F

H
SEM860F

CO-11
THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
THERMOSTAT AND THERMOSTAT HOUSING PFP:21200

Removal and Installation EBS006BX

WLC018

CAUTION:
Be careful not to spill coolant over the engine compartment. Use a rag to absorb any spilled coolant.
1. Drain engine coolant. Refer to MA-15, "DRAINING ENGINE COOLANT" .
2. Disconnect the lower radiator hose.
3. Remove water inlet thermostat housing, then remove the thermostat.
4. Before installing the thermostat, make sure the gum ring is prop-
erly seated around the thermostat.

SEM862F

5. Install thermostat with jiggle valve or air bleeder at upper side.
6. Refill engine coolant. Refer to MA-16, "REFILLING ENGINE
COOLANT" .
After installation, run engine for a few minutes, and check
for any coolant leaks.

SEM863F

CO-12
THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
Inspection EBS006BY

A
1. Check for valve seating condition at normal room temperature.
The valve should seat tightly all the way around. If the valve is
warped or stuck open, replace the thermostat.
2. Suspend the thermostat, by a string caught in the closed valve, CO
in boiling water while monitoring the temperature.
Valve opening temperature

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