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ENGINE COOLING SYSTEM
B ENGINE
A
ENGINE COOLING SYSTEM
SECTION CO CO
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 2. COOLING FAN ......................................................... 19
. F
Precautions For Liquid Gasket ................................ 2 . Components (Crankshaft Driven Type) ................. 19 .
LIQUID GASKET APPLICATION PROCEDURE 2 ..... Removal and Installation ....................................... 19 .
PREPARATION .......................................................... 3
. REMOVAL .......................................................... 19
. G
Special Service Tools .............................................. 3. INSPECTION AFTER REMOVAL ...................... 19 .
Commercial Service Tools ....................................... 3 . INSTALLATION .................................................. 19 .
OVERHEATING CAUSE ANALYSIS ......................... 4 . Removal andInstallation (Motor Driven Type) (Mod-
H
Troubleshooting Chart ............................................. 4 . els with A/C) .......................................................... 19
.
COOLING SYSTEM ................................................... 6 . REMOVAL .......................................................... 19
.
Cooling Circuit ......................................................... 6
. INSTALLATION .................................................. 20 .
ENGINE COOLANT ................................................... 7 . WATER PUMP ......................................................... 21
. I
Inspection ................................................................ 7
. Components .......................................................... 21
.
LEVEL CHECK .................................................... 7 . Removal and Installation ....................................... 21 .
CHECKING RADIATOR SYSTEM FOR LEAKS 7 ..... REMOVAL .......................................................... 21
. J
Changing Engine Coolant ....................................... 7 . INSPECTION AFTER REMOVAL ...................... 22 .
DRAINING ENGINE COOLANT .......................... 8 . INSTALLATION .................................................. 22 .
REFILLING ENGINE COOLANT ......................... 8 . INSPECTION AFTER INSTALLATION ............... 22 .
K
FLUSHING COOLING SYSTEM .......................... 9 . THERMOSTAT AND WATER PIPING ..................... 23 .
RADIATOR ................................................................11
. Components .......................................................... 23
.
Components ...........................................................11
. Removal and Installation ....................................... 24 .
Removal and Installation ........................................11 . REMOVAL .......................................................... 24
. L
REMOVAL ...........................................................11
. INSPECTION AFTER REMOVAL ...................... 24 .
INSPECTION AFTER REMOVAL ...................... 13 . INSTALLATION .................................................. 24 .
INSTALLATION .................................................. 14 . INSPECTION AFTER INSTALLATION ............... 25 . M
INSPECTION AFTER INSTALLATION .............. 14 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 26 .
RADIATOR (ALUMINUM TYPE) ............................. 15 . Standard and Limit ................................................. 26
.
Components .......................................................... 15
. ENGINE COOLANT CAPACITY ......................... 26 .
Disassembly and Assembly .................................. 15 . THERMOSTAT ................................................... 26 .
PREPARATION .................................................. 15 . RESERVOIR TANK ............................................ 26 .
DISASSEMBLY .................................................. 15 .
ASSEMBLY ........................................................ 16.
INSPECTION ..................................................... 18 .
CO-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions For Liquid Gasket EBS01E6J
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
q Remove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser [SST].
Use Genuine Liquid Gasket or equivalent.
q Within five minutes of liquid gasket application, install the mat-
ing component.
q If liquid gasket protrudes, wipe it off immediately.
q Do not retighten mounting bolts or nuts after the installation.
q After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
PBIC2160E
CO-2
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools EBS01E6K
Tool number
Description
Tool name CO
WS39930000 Pressing the tube of liquid gasket
Tube presser
C
D
S-NT052
EG17650301 Adapting radiator cap tester to radiator cap
Radiator cap tester adapter and radiator filler neck E
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in) F
S-NT564
KV99103510 Installing radiator upper and lower tanks G
Radiator plate pliers A
H
S-NT224
I
KV99103520 Removing radiator upper and lower tanks
Radiator plate pliers B
J
S-NT225 K
Commercial Service Tools EBS01E6L
Tool name Description L
Radiator cap tester Checking radiator and reservoir tank cap
M
PBIC1982E
CO-3
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS PFP:00012
Troubleshooting Chart EBS01E6M
Symptom Check items
Water pump malfunction Worn or loose drive belt
Thermostat stuck closed --
Dust contamination or
Poor heat transfer Damaged fins paper clogging --
Physical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Refer to EC-132, "DTC
Cooling fan does not oper-
P0217 ENGINE OVER
ate
TEMPERATURE"
Reduced air flow --
High resistance to fan rota-
tion Fan assembly
Damaged fan blades
Damaged radiator shroud -- -- --
Cooling sys- Improper engine coolant
-- -- --
tem parts mixture ratio
malfunction Poor engine coolant quality -- Engine coolant density --
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
CO-4
OVERHEATING CAUSE ANALYSIS
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for
Abusive driving CO
extended time
Driving at extremely high
speed
-- Overload on engine C
Powertrain system mal-
function
Installed improper size
Except cool- --
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper --
Installed car brassiere
Blocked radiator grille Mud contamination or F
Blocked or restricted air paper clogging --
flow
Blocked radiator --
Blocked condenser G
Blocked air flow
Installed large fog lamp
H
I
J
K
L
M
CO-5
COOLING SYSTEM
COOLING SYSTEM PFP:21020
Cooling Circuit EBS01E6N
PBIC4099E
CO-6
ENGINE COOLANT
ENGINE COOLANT PFP:KQ100
A
Inspection EBS01E6P
LEVEL CHECK
q Check if the reservoir tank engine coolant level within MIN to CO
MAX when engine is cool.
q Adjust engine coolant level as necessary.
C
D
SMA412B
E
CHECKING RADIATOR SYSTEM FOR LEAKS
q To check for leaks of cooling system, apply pressure to the res-
ervoir tank (1) with the radiator cap tester (commercial service F
tool) (A) and the radiator cap tester adapter (B) [SST:
EG17650301].
Testing pressure: G
157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING: H
Do not remove reservoir tank cap and/or radiator cap when
engine is hot. Serious burns could occur from high pres-
sure engine coolant escaping from reservoir tank and/or PBIC3501E
radiator. I
CAUTION:
Higher test pressure than specified may cause cooling system damage.
NOTE: J
In a case that engine coolant decreases, replenish radiator and reservoir tank with engine coolant.
q If anything is found, repair or replace damaged parts.
K
Changing Engine Coolant EBS01E6Q
WARNING:
q To avoid being scalded, do not change engine coolant when engine is hot. L
q Wrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to
release built-up pressure. Then turn cap all the way.
q Be careful not to allow engine coolant to contact drive belts. M
CO-7
ENGINE COOLANT
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and
remove radiator cap.
2 : Engine under cover (front)
A : Loosen.
: Vehicle front
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
PBIC3634E
When draining all engine coolant in the system, also perform the following steps.
2. Remove air relief plug (1) on heater feed tube.
q LHD models
2 : Water hose (from reservoir tank)
3 : Fuel filter
: Vehicle front
PBIC3348E
q RHD models
2 : Water hose (from reservoir tank)
: Vehicle front
PBIC3635E
3. Open cylinder block drain plug. Refer to EM-110, "CYLINDER BLOCK" .
4. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
5. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer to CO-9, "FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.
Radiator drain plug:
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