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ENGINE COOLING SYSTEM
B ENGINE
A
CO
SECTION
ENGINE COOLING SYSTEM C
D
E
CONTENTS
QG THERMOSTAT AND THERMOSTAT HOUSING ..... 20 . F
Removal and Installation ....................................... 20
.
PRECAUTIONS ......................................................... 3. REMOVAL .......................................................... 20
.
Precautions For Liquid Gasket ................................ 3 . INSPECTION AFTER REMOVAL ...................... 21 . G
REMOVAL OF LIQUID GASKET SEALING ......... 3 . INSTALLATION .................................................. 21
.
LIQUID GASKET APPLICATION PROCEDURE 3 ..... SERVICE DATA AND SPECIFICATIONS (SDS) ..... 22 .
PREPARATION .......................................................... 4
. Standard and Limit ............................................... .. 22
.
Special Service Tools .............................................. 4. H
CAPACITY .......................................................... 22
.
OVERHEATING CAUSE ANALYSIS ......................... 5 . THERMOSTAT ................................................... 22
.
Troubleshooting Chart ............................................. 5 . RADIATOR ......................................................... 22
.
COOLING SYSTEM ................................................... 7 . Tightening Torque .................................................. 22
. I
Cooling Circuit ......................................................... 7
.
ENGINE COOLANT ................................................... 8 .
Inspection ................................................................ 8
.
QR
J
LEVEL CHECK .................................................... 8 . PRECAUTIONS ....................................................... 23 .
LEAK CHECK ...................................................... 8 . Precautions For Liquid Gasket ............................ .. 23 .
Changing Engine Coolant ....................................... 8 . REMOVAL OF LIQUID GASKET ........................ 23 .
DRAINING ENGINE COOLANT .......................... 8 . K
LIQUID GASKET APPLICATION PROCEDURE 23 ...
REFILLING ENGINE COOLANT ......................... 8 . PREPARATION ........................................................ 24.
FLUSHING COOLING SYSTEM .......................... 9 . Special Service Tools .......................................... .. 24.
RADIATOR ................................................................11
. OVERHEATING CAUSE ANALYSIS ..................... .. 25 . L
Removal and Installation ........................................11 . Troubleshooting Chart ........................................... 25 .
REMOVAL ...........................................................11
. COOLING SYSTEM ................................................. 27 .
INSTALLATION .................................................. 12 . Cooling Circuit ....................................................... 27
. M
Disassembly and Assembly of Cooling Fan .......... 12 . ENGINE COOLANT ............................................... .. 29 .
DISASSEMBLY .................................................. 12 . Inspection .............................................................. 29
.
ASSEMBLY ........................................................ 12. LEVEL CHECK ................................................... 29 .
CHECKING RADIATOR CAP ............................. 12 . LEAK CHECK ..................................................... 29 .
CHECKING RADIATOR ..................................... 13 . Changing Engine Coolant ...................................... 29 .
RADIATOR (ALUMINUM TYPE) ............................. 14 . DRAINING ENGINE COOLANT ......................... 29 .
Disassembly and Assembly .................................. 14 . REFILLING ENGINE COOLANT ........................ 29 .
PREPARATION .................................................. 14 . FLUSHING COOLING SYSTEM ........................ 30 .
DISASSEMBLY .................................................. 14 . RADIATOR ............................................................... 31
.
ASSEMBLY ........................................................ 15. Removal and Installation ....................................... 31 .
INSPECTION ..................................................... 17 . REMOVAL .......................................................... 31
.
WATER PUMP ......................................................... 18.
Removal and Installation ....................................... 18 .
REMOVAL .......................................................... 18
.
INSPECTION AFTER REMOVAL ...................... 18 .
INSTALLATION .................................................. 19 .
INSPECTION AFTER INSTALLATION .............. 19 .
CO-1
INSTALLATION ................................................... 31
. COOLING SYSTEM .................................................47 .
Disassembly and Assembly of Cooling Fan .......... 32 . Cooling Circuit ........................................................47
.
DISASSEMBLY .................................................. 32
. ENGINE COOLANT ............................................... ..49 .
ASSEMBLY ........................................................ 32
. Inspection ............................................................. ..49
.
CHECKING RADIATOR CAP ............................. 32 . LEVEL CHECK ...................................................49 .
CHECKING RADIATOR ..................................... 33 . LEAK CHECK .....................................................49 .
RADIATOR (ALUMINUM TYPE) .............................. 34 . Changing Engine Coolant ......................................49 .
Disassembly and Assembly ................................... 34 . DRAINING ENGINE COOLANT .........................49 .
PREPARATION .................................................. 34
. REFILLING ENGINE COOLANT ........................50 .
DISASSEMBLY .................................................. 34
. FLUSHING COOLING SYSTEM ........................51 .
ASSEMBLY ........................................................ 35
. RADIATOR ...............................................................52
.
INSPECTION ...................................................... 37
. Removal and Installation ........................................52 .
WATER PUMP .......................................................... 38
. REMOVAL ...........................................................52.
Removal and Installation ....................................... 38
. INSTALLATION ...................................................52 .
REMOVAL .......................................................... 38
. Disassembly and Assembly Radiator Fan .............53 .
INSPECTION AFTER REMOVAL ....................... 39 . DISASSEMBLY ...................................................53 .
INSTALLATION ................................................... 39
. ASSEMBLY .........................................................53 .
INSPECTION AFTER INSTALLATION ............... 39 . Checking Radiator Cap ........................................ ..53 .
THERMOSTAT AND WATER CONTROL VALVE .... 40 . Checking Radiator .................................................54 .
Removal and Installation ....................................... 40
. RADIATOR (ALUMINUM TYPE) ..............................55 .
REMOVAL .......................................................... 40
. Disassembly and Assembly ................................. ..55 .
INSPECTION AFTER REMOVAL ....................... 41 . PREPARATION ...................................................55 .
INSTALLATION ................................................... 41
. DISASSEMBLY ...................................................55 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 42 . ASSEMBLY .........................................................56 .
Standard and Limit ................................................. 42
. INSPECTION .................................................... ..58 .
CAPACITY .......................................................... 42
. WATER PUMP ..........................................................59 .
THERMOSTAT ................................................... 42
. Removal and Installation ........................................59 .
WATER CONTROL VALVE ................................ 42 . REMOVAL ...........................................................59.
RADIATOR ......................................................... 42
. INSPECTION AFTER REMOVAL ..................... ..59 .
Tightening Torque .................................................. 42
. INSTALLATION ...................................................60 .
INSPECTION AFTER INSTALLATION ...............60 .
YD THERMOSTAT AND WATER PIPING ......................61 .
Removal and Installation ........................................61 .
PRECAUTIONS ........................................................ 43
. REMOVAL ...........................................................61.
Precautions For Liquid Gasket .............................. 43 . INSPECTION AFTER REMOVAL ..................... ..62 .
REMOVAL AND LIQUID GASKET ..................... 43 . INSTALLATION ...................................................62 .
LIQUID GASKET APPLICATION PROCEDURE 43 ... SERVICE DATA AND SPECIFICATIONS (SDS) .....63 .
PREPARATION ........................................................ 44
. Standard and Limit ............................................... ..63.
Special Service Tools ............................................ 44
. CAPACITY ..........................................................63.
OVERHEATING CAUSE ANALYSIS ....................... 45 . THERMOSTAT ....................................................63 .
Troubleshooting Chart ........................................... 45
. RADIATOR ..........................................................63.
Tightening Torque ..................................................63 .
CO-2
PRECAUTIONS
[QG]
PRECAUTIONS
[QG] PFP:00001
A
Precautions For Liquid Gasket EBS00GPU
REMOVAL OF LIQUID GASKET SEALING
q After removing the mounting bolts and nuts, separate the mating CO
surface using a seal cutter and remove the liquid gasket.
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 gasket area.
CAUTION:
D
If for some unavoidable reason a tool such as a flat-bladed
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 liquid gasket adhering to the
gasket application surface and the mating surface. F
q Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with G
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser. H
Use Genuine Liquid Gasket or equivalent.
PBIC0003E
I
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
q If there is a groove for the liquid gasket application, apply the J
gasket to the groove.
K
L
EMA0622D
M
q As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
q Within five minutes of gasket application, install the mating com-
ponent.
q If the liquid gasket 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 oil and coolant.
CAUTION: SEM164F
If there are additional instructions in this manual, observe them.
CO-3
PREPARATION
[QG]
PREPARATION PFP:00002
Special Service Tools EBS00GPV
Tool number
Description
Tool name
WS39930000 Pressing the tube of liquid gasket
Tube presser
S-NT052
EG17650301 Adapting radiator cap tester to radiator filler
Radiator cap tester adapter neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-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
[QG]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS00GPW
Symptom Check items
Water pump malfunction Worn or loose drive belt CO
Thermostat stuck closed --
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- -- --
tion
Damaged fan blades
F
Damaged radiator shroud -- -- --
Improper coolant mixture
Cooling sys- -- -- --
ratio 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
M
CO-5
OVERHEATING CAUSE ANALYSIS
[QG]
Symptom Check items
High engine rpm under no
load
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
-- 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 contamination or
Blocked or restricted air paper clogging --
flow
Blocked radiator --
Blocked condenser
--
Installed large fog lamp
CO-6
COOLING SYSTEM
[QG]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS00GPX
CO
C
D
E
F
G
H
I
J
K
L
M
PBIC0644E
CO-7
ENGINE COOLANT
[QG]
ENGINE COOLANT PFP:KQ100
Inspection EBS00GPY
LEVEL CHECK
q Check if the reservoir tank coolant level is within MIN to MAX
when engine is cool.
q Drain or refill coolant when it is too much or too little.
SMA412B
LEAK CHECK
q To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
SLC134B
Changing Engine Coolant EBS00GPZ
WARNING:
q To avoid being scalded, never change the coolant when the engine is hot.
q Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Remove undercover.
2. Disconnect radiator lower hose and remove radiator cap.
CAUTION:
Be careful not to allow coolant to contact drive belts.
3. Open drain plugs on cylinder block.
4. Remove reservoir tank and drain coolant.
5. Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer to CO-9,
"FLUSHING COOLING SYSTEM" .
PBIC0638E
REFILLING ENGINE COOLANT
1. Install reservoir tank, radiator drain plug and cylinder block drain plug.
Apply sealant to the thread of cylinder block drain plug.
q Use Genuine Liquid Gasket or equivalent.
CO-8
ENGINE COOLANT
[QG]
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