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ENGINE

                                                                                                                                                                       A




                                                                             ENGINE COOLING SYSTEM
                                                                                                    SECTION                    CO                                      CO



                                                                                                                                                                       C


                                                                                                                                                                       D


                                                                                                                                                                       E
                                                                    CONTENTS
FUNCTION DIAGNOSIS .............................. 2
                                             .                                       ON-VEHICLE REPAIR ................................ 13
                                                                                                                                    .                                  F

DESCRIPTION ................................................... 2
                                                          .                          RADIATOR ........................................................ 13
  Engine Cooling System .......................................... 2
                                                            .                          Exploded View ........................................................13
                                                                                                                                                             .         G
  Engine Cooling System Schematic ........................ 2.                          Removal and Installation ........................................13   .
                                                                                       Inspection ...............................................................15
                                                                                                                                                             .
SYMPTOM DIAGNOSIS .............................. 3
                                            .
                                                                                     COOLING FAN .................................................. 16                 H
OVERHEATING CAUSE ANALYSIS ................. 3
                                       .                                               Exploded View ........................................................16
                                                                                                                                                             .
  Troubleshooting Chart ............................................. 3
                                                               .                       Removal and Installation ........................................16   .
                                                                                       Disassembly and Assembly ....................................16       .          I
PRECAUTION .............................................. 5
                                                     .                                 Inspection ...............................................................17
                                                                                                                                                             .
PRECAUTIONS .................................................. 5
                                                         .                           WATER PUMP .................................................. 18
  Precaution for Supplemental Restraint System                                         Exploded View ........................................................18
                                                                                                                                                             .         J
  (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                              Removal and Installation ........................................18   .
  SIONER" .................................................................. 5
                                                                      .                Inspection ...............................................................20
                                                                                                                                                             .
                                                                                                                                                                       K
PREPARATION ........................................... 6
                                                   .                                 WATER INLET AND THERMOSTAT ASSEM-
PREPARATION .................................................. 6
                                                         .                           BLY .................................................................... 21
                                                                                       Exploded View ........................................................21
                                                                                                                                                             .
  Commercial Service Tools ...................................... 6
                                                           .                                                                                                           L
                                                                                       Removal and Installation ........................................21   .
ON-VEHICLE MAINTENANCE .................... 7
                                       .                                               Inspection ...............................................................22
                                                                                                                                                             .

ENGINE COOLANT ........................................... 7
                                                     .                               WATER OUTLET AND WATER PIPING .......... 23                                       M
  Inspection ................................................................. 7
                                                                          .            Exploded View ........................................................23
                                                                                                                                                             .
  Draining .................................................................... 7
                                                                          .            Removal and Installation ........................................23   .
  Refilling .................................................................... 8
                                                                          .            Inspection ...............................................................24
                                                                                                                                                             .         N
  Flushing .................................................................... 9
                                                                          .
                                                                                     SERVICE DATA AND SPECIFICATIONS
RADIATOR ........................................................11
                                                             .                       (SDS) ........................................................... 25
                                                                                                                                                   .
                                                                                                                                                                       O
RADIATOR CAP ....................................................... 11
                                                                .                    SERVICE DATA AND SPECIFICATIONS
 RADIATOR CAP : Inspection ................................. 11 .                    (SDS) ................................................................. 25
                                                                                       Periodical Maintenance Specification ...................25             .        P
RADIATOR ............................................................... 11
                                                                    .
                                                                                       Radiator ..................................................................25
                                                                                                                                                              .
 RADIATOR : Inspection ......................................... 11 .
                                                                                       Thermostat .............................................................25
                                                                                                                                                              .




Revision: 2007 November                                                        CO-1                                                                 2008 EX35
                             DESCRIPTION
< FUNCTION DIAGNOSIS >
FUNCTION DIAGNOSIS
DESCRIPTION
Engine Cooling System                        INFOID:0000000003139274




                                           JPBIA1830GB




Engine Cooling System Schematic              INFOID:0000000003139275




                                           PBIC5028E




Revision: 2007 November           CO-2            2008 EX35
                                      OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS                                                                                                                                 A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart                                                                                                   INFOID:0000000003139276
                                                                                                                                                  CO


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


                                                                                                                                                  N



                                                                                                                                                  O



                                                                                                                                                  P




Revision: 2007 November                                         CO-3                                                            2008 EX35
                                      OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS >
                                            Symptom                                                  Check items
                                                                                                           High engine rpm under no
                                                                                                           load
                                                                                                           Driving in low gear for ex-
                                                                           Abusive driving
                                                                                                           tended time
                                                                                                           Driving at extremely high
                                                                                                           speed
                             --                 Overload on engine
                                                                           Powertrain system malfunc-
                                                                           tion
                                                                           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 contamination or paper
                Blocked or restricted air                                  clogging                                     --
                flow
                                                Blocked radiator                        --
                                                Blocked condenser
                                                                           Blocked air flow
                                                Installed large fog lamp




Revision: 2007 November                                            CO-4                                                      2008 EX35
                                              PRECAUTIONS
< PRECAUTION >
PRECAUTION                                                                                                                     A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT                                                    CO
PRE-TENSIONER"                                                                                       INFOID:0000000003657648



The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along                                  C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.                      D
Information necessary to service the system safely is included in the "SRS AIRBAG" and "SEAT BELT" of this
Service Manual.
WARNING:                                                                                                                       E



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