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B ENGINE

CO
SECTION
ENGINE COOLING SYSTEM C

E
CONTENTS
QG18DE SERVICE DATA AND SPECIFICATIONS (SDS) ..... 19 . F
Thermostat ............................................................ 19
.
PRECAUTIONS ......................................................... 3. Radiator ................................................................. 19
.
Precautions For Liquid Gasket ................................ 3 .
G
REMOVAL OF LIQUID GASKET ......................... 3 .
LIQUID GASKET APPLICATION PROCEDURE 3 .....
QR25DE
PREPARATION .......................................................... 4
. PRECAUTIONS ....................................................... 20
.
Special Service Tools .............................................. 4. H
Precautions For Liquid Gasket .............................. 20 .
OVERHEATING CAUSE ANALYSIS ......................... 5 . REMOVAL OF LIQUID GASKET ........................ 20 .
Troubleshooting Chart ............................................. 5 . LIQUID GASKET APPLICATION PROCEDURE 20 ...
COOLING SYSTEM ................................................... 6 . PREPARATION ........................................................ 21
. I
Cooling Circuit ......................................................... 6
. Special Service Tools ............................................ 21
.
ENGINE COOLANT ................................................... 7 . OVERHEATING CAUSE ANALYSIS ....................... 22 .
System Check ......................................................... 7
. Troubleshooting Chart ........................................... 22. J
CHECKING COOLING SYSTEM HOSES ........... 7 . COOLING SYSTEM ................................................. 23 .
CHECKING RESERVOIR LEVEL ........................ 7 . Cooling Circuit ....................................................... 23
.
CHECKING COOLING SYSTEM FOR LEAKS..... 7 ENGINE COOLANT ................................................. 24 .
CHECKING RADIATOR ....................................... 7 . K
System Check ....................................................... 24
.
CHECKING RADIATOR CAP ............................... 8 . CHECKING COOLING SYSTEM HOSES .......... 24 .
Refilling Engine Coolant .......................................... 8 . CHECKING RESERVOIR LEVEL ...................... 24 .
WATER PUMP ........................................................... 9
. CHECKING COOLING SYSTEM FOR LEAKS ... 24 L
Removal and Installation ......................................... 9 . CHECKING RADIATOR ..................................... 24 .
Inspection .............................................................. 10
. CHECKING RADIATOR CAP ............................. 25 .
THERMOSTAT AND THERMOSTAT HOUSING ......11 . Refilling Engine Coolant ........................................ 25. M
Removal and Installation ........................................11 . WATER PUMP ......................................................... 26
.
Inspection .............................................................. 12
. Removal and Installation ....................................... 26 .
RADIATOR ............................................................... 13
. REMOVAL .......................................................... 26
.
Removal and Installation ....................................... 13 . INSPECTION AFTER REMOVAL ...................... 27 .
REMOVAL .......................................................... 13
. INSTALLATION .................................................. 27.
INSTALLATION .................................................. 13 . INSPECTION AFTER INSTALLATION ............... 27 .
Disassembly and Assembly .................................. 14 . THERMOSTAT AND THERMOSTAT HOUSING ..... 28 .
PREPARATION ................................................. 14 . Removal and Installation ....................................... 28 .
DISASSEMBLY .................................................. 14 . REMOVAL .......................................................... 28
.
ASSEMBLY ........................................................ 15. INSPECTION AFTER REMOVAL ...................... 29 .
Inspection .............................................................. 17
. INSTALLATION .................................................. 29.
COOLING FAN ........................................................ 18. RADIATOR ............................................................... 30
.
Disassembly and Assembly Radiator Cooling Fan 18 ... Removal and Installation ....................................... 30 .
DISASSEMBLY .................................................. 18 . REMOVAL .......................................................... 30
.
ASSEMBLY ........................................................ 18. INSTALLATION .................................................. 30.
Disassembly and Assembly ................................... 31 .

CO-1
PREPARATION .................................................. 31 . COOLING FAN .........................................................36 .
DISASSEMBLY .................................................. 31 . Disassembly and Assembly ...................................36 .
ASSEMBLY ........................................................ 32. DISASSEMBLY ...................................................36 .
INSPECTION ...................................................... 34. ASSEMBLY .........................................................36 .
Inspection .............................................................. 34
. SERVICE DATA AND SPECIFICATIONS (SDS) .....37 .
CHECKING RADIATOR CAP ............................. 34 . Capacity .................................................................37
.
CHECKING RADIATOR ..................................... 34 . Thermostat .............................................................37
.
Water Control Valve ...............................................37 .
Radiator .................................................................37
.

CO-2
PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Precautions For Liquid Gasket EBS00EYR

REMOVAL OF LIQUID GASKET
q After removing the mounting bolts and nuts, disconnect and CO
remove the sealant using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
C
q In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the liquid gasket applied area.
CAUTION:
D
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating sur-
faces.
PBIC0275E
E
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old sealant adhering to the applica-
tion surface and the mating surface. F
q Remove the old sealant completely from the groove of the appli-
cation surface, mounting bolts, and bolt holes.
2. Thoroughly clean the application surface and the mating surface G
to remove adhering moisture, grease and foreign material.
3. Attach the sealant tube to the tube presser.
Use Genuine RTV Silicone Sealant or equivalent. Refer to H
GI-44, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
PBIC0003E

I
4. Apply the sealant without breaks to the specified location with
the specified dimensions.
q If there is a groove for the sealant application, apply the sealant J
to the groove.

L
EMA0622D

M
q As for the bolt holes, normally apply the sealant inside the holes.
Occasionally, it should be applied outside the holes.
q Within five minutes of sealant application, install the mating
component.
q If the sealant protrudes, wipe it off immediately.
q Do not retighten after the installation.
q After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-13,
"RECOMMENDED FLUIDS AND LUBRICANTS" .
SEM164F

CO-3
PREPARATION
[QG18DE]
PREPARATION PFP:00002

Special Service Tools EBS00CH2

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
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 EBS00CH3

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
Reduced air flow High resistance to fan rota- Engine cooling fans --
tion
Damaged fan blades
F
Damaged radiator shroud -- Fan shroud --
Improper coolant mixture
Cooling sys- -- --
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
High engine RPM under no
load
M
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
Over heating engine Overload on engine
Powertrain system mal-
Except cool- function
ing system
Installed improper size
parts mal- --
wheels and tires
function
Dragging brakes
Improper ignition timing
Blocked radiator grille Installed car brassiere

Blocked or restricted air Blocked bumper
Mud, debris, or paper clog- --
flow Blocked radiator
ging
Blocked condenser

CO-5
COOLING SYSTEM
[QG18DE]
COOLING SYSTEM PFP:21020

Cooling Circuit EBS00CH4

WBIA0132E

CO-6
ENGINE COOLANT
[QG18DE]
ENGINE COOLANT PFP:KQ100
A
System Check EBS00CH5

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure CO
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.
C
CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
q Improper attachment D
q Leaks
q Cracks
q Damage E
q Loose connections
q Chafing
F
q Deterioration
CHECKING RESERVOIR LEVEL
q Check if the reservoir tank coolant level is within MIN to MAX G
when the engine is cool.
q Adjust coolant level if it is too much or too little.
H

SMA412B J

CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
K
tester.
Testing pressure : 157 kPa (1.6 kg/cm2 , 23 psi)
WARNING: L
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator. M
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 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).

CO-7
ENGINE COOLANT
[QG18DE]
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
6. Check for leakage.
CHECKING RADIATOR CAP
q To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief
pressure
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 ,
11 - 14 psi)
Limit : 59 kPa (0.6 kg/cm2 , 9 psi)

SLC755A

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

SMA967B

Refilling Engine Coolant EBS00CH6

Changing the engine coolant is part of the required maintenance of the engine. Refer to MA-16, "Changing
Engine Coolant" .

CO-8
WATER PUMP
[QG18DE]
WATER PUMP PFP:21020
A
Removal and Installation EBS00CH7

WLC017
G
CAUTION:
q When removing water pump assembly, be careful not to get coolant on drive belt.
H
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-7, "CHECKING
COOLING SYSTEM FOR LEAKS" .
I
1. Drain engine coolant.
Refer to MA-16, "DRAINING ENGINE COOLANT" .

L
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-9
WATER PUMP
[QG18DE]
7. Remove the water pump bolts.
8. Remove the water pump.
q Remove liquid gasket from water pump and mating surface of
cylinder block using a scraper.
9. Installation is in the reverse order of removal.
q When applying liquid gasket to mating surface of water pump,
use Genuine Anaerobic Liquid Gasket or equivalent. Refer to
GI-44, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
q When filling radiator with coolant, refer to MA-17, "REFILLING SEM859F
ENGINE COOLANT" .
q When installing drive belts, refer to MA-16, "Checking Drive Belts" .

Inspection EBS00CH8

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.

SEM860F

CO-10
THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
THERMOSTAT AND THERMOSTAT HOUSING PFP:21200
A
Removal and Installation EBS00CH9

WBIA0134E
G
CAUTION:
Be careful not to spill coolant over the engine compartment. Use a rag to absorb any spilled coolant.
H
1. Drain engine coolant. Refer to MA-16, "DRAINING ENGINE COOLANT" .
2. Disconnect the lower radiator hose.
3. Remove water inlet thermostat housing, then remove the thermostat.
I
4. Before installing the thermostat, make sure the gum ring is prop-
erly seated around the thermostat.
J

L
SEM862F

5. Install thermostat with jiggle valve or air bleeder at upper side. M
6. Refill engine coolant after installation. Run engine for a few min-
utes, and check for any coolant leaks. Refer to MA-17, "REFILL-
ING ENGINE COOLANT"

SEM863F

CO-11
THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
Inspection EBS00CHA

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,
in boiling water while monitoring the temperature.
Valve opening temperature

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