E

COOLING SYSTEM

1NDEX . ..*....*~.....*..*~~**~=~~.~~.~...~..**.~.....*...~.. E- 2

OUTLINE .................................................. E- 4
OUTLlNE OF CONSTRUCTION.. ................ E- 4
COOLANT FLOW CHART.. ....................... E- 4
SPECIFICATKINS .................................... E- 5
TWO-STAGE THERMOSTAT.. .................... E- 6
RADIATOR AND COOLING FAN.. .............. E- 7
ELECTRIC COOLING FAN SYSTEM ........... E- 8

SUPPLEMENTAL SERVICE INFORMATION E- 9

THERMOSTAT .......................................... E- 9
INSPECTION .......................................... E- 9
ELECTRIC COOLING FAN SYSTEM ............ E-l 0
SYSTEM INSPECTlON .............................. E-l 0
FAN MOTOR ............................................. E-If
iNSPECTION .......................................... E-l 1
WATER THERMOSWITCH .......................... E-l I
INSPECTION .......................................... E-f 1
RADIATOR THERMOSWITCH ..................... E-l 2
REMOVAL I INSPECTION I INSTALLATION.. E-12
FAN RELAY .............................................. E-l 3
REMOVAL I tNSPECTlUN .......................... E-l 3
93GOEX-701
E tNDEX

INDEX

-
- &ANT RESERVOlR
ENGiNE COOLANT
TOTAL CAPACITY
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt. 5.3 tmp qt)

1. Fan motor
Inspection .._.....,._............._.......... page E-1 I

E-Z
 INDEX E
BP DOHC TURBO

III6
No.2 AND No.3 RELAY

1. Thermostat 4. Water thermoswitch

Inspection ................................... page E- 9 inspection ................................... page E-l 1
2. Electric cooling fan system 5. Radiator thermoswitch
System inspection ....................... page E-l 0 Removal I Inspection I
3. Fan motor Instailation ................................. page E-1 2
Inspection ................................... page E-l 1 6 Fan relay
Removal I Inspection .................. page E-1 3

E-3
E OUTLINE

OUTLINE
OUTttNE OF CONSTRUCTION
The cooling system in the 323 4WD model is basically the same as in the 323 2WD model.
Although there is no fundamental change from the BP DOHC of the 2WD model, the coolant circulation
path has been changed to direct coolant to the water-cooied turbocharger.
A two-stage thermostat is used in the BP DUHC turbocharged engine to stabilize the engine coolant tem-
peratu re.
The radiator and cooling fan specifications are different. The BP DOHC turbocharged engine of the 4WD
model uses a two-speed electric cooling fan.
93GOEX-704

COOLANT FLOW CHART (BP DOHC TURBO)

E-4
SPECIFICATlONS

- EnginelTtansaxte 8P SOHC ] 8P DOW Turbo

km MTX ATX I MTX
Cootlng system Water-cooled, forced crrculation
lrters [US Qt. Imo at) 5.0 (5.3, 4.4) 6.0 t&3,5.3)
-Coolant camacltv I
1 Type Centrifugal
Water puma 1
I Water seal Unified mechanical seal
I

: Type Wax,single stage”‘, Wax, two-stage*’ 1 Wax, two-stage

80.5-83.5 (177-182)“1
Main: 86.5-89.5 (lSS--193)
Opening temperature “C (OF) Main: 86.5-89.5 (188-l 93) *’
Sub 83.G86.5 (182-188)
Sub : 83.5-86.5 (182-188)
The:mosta! 1
1 Full-open temperature OC (OF) 95 (203)*‘, 100 (212)*’ i 100 (212)
8.5 (0.335) or more’l
* Main: 8.0 (0.31) min.
j Full-open lift mm (in) Main: 8.0 (0.31).mln.‘2
Sub : I.5 (0.06) mm.
Sub : 1.5 10.061 min
1 Type Corrugated fin
Radiator Cap vaive opening-pressure ’ 74-l 03 (0.75-I .05, 11-l 5)
kPa (kglcm2, psi)
j Tvm? EIectnc I
f Outer drameter mm (in) 320 (12.6) 340 (13.4)
Blade
Coohg fan Number 4 5
Hi : 13.3 + 10% max.
Motor Current A 6.6 * 1
/ Lo: 8.8 + 10% max.
L I 1 r 1

93GOEX-706
“...Except cold area, *2...Cotd area only

E-5
E OUTlANE
TWO-STAGE THERMOSTAT (BP DOHC TURBO)

MAIN VALVE

SINGLE-STAGE THERMOSTAT
(AMBIENT fEMP. -20% (4*f))
NTRANCE PORT TEMP

GINE EXIT PORT TEMP.

100 km/h 60 kndh

(63 mph) ~~~~~ (38 mph)

TWO-STAGE THERMOSTAT

A sub-valve is incorporated in the thermostat to stabilize the coolant temperature in the engine, to improve
cold weather performance, and to reduce heater output temperature fluctuations as noted in the diagram.

Operation
Stage 1
During cold weather operation, 83.5*C [182°F]-86.50C [t 88OF] only the sub-valve opens to control the
engine coolant temperature.

Stage 2
During normal operation, 86.5OC (1 88°F)-89.50C (I 93OF) the main valve opens to permit increased coul-
an: flow through the radiator.

E-6
RADIATOR AND COOLING FAN
The radiator and cooling fan specifications are revised.

Specifications
r
EnginelTransaxle BP SOHC 1 BP DOHC Turbo
MTX ATX I MTX
Item
1 Radiator I
Width 647 + +
Core size mm (in) H etght 390 t *-
Depth 16 25 e
Fm pnch mm (in) 1.3 t c
Heat dissipaton capacity kcallh 38,800 43,800 C
Type - Double tube -
Transaxle oil cooler Heat dissipation capacity - 1,650 -
kcal/h I
Cooling fan
Number of biades 4 5 +
Outer drameter mm (in> 320 340 C
Capacity w-v 80-12 160-12 c
Current A Hi : 13.3 + 70% max. +
6.6 * 1 Lo: 8.8 + 10% max.
1 I
93GOEX-708

DEPTH

OIL COOLER (ATX

;ECTION A-A
4WD MODEL ZWD MODEL
I

E-7
E OUTLINE
ELECTRIC COCUNG FAN SYSTEM (BP DOHC TURBO)
System Circuit

I I
WITH A/C
r----‘-- -___- ---------.--------;

II 1
A/C RELAY

+IIAGNOSlS
CONNECTOR

WATER
ADDITIONAL
THERMOSWlTCH
FAN
ABOVE 97% (207OF): ON
MOTOR

RAD1ATdTHERMOSWITCH
ABOVE 105% I221 OF-): ON

Operation
1. When the coolant temperature exceeds 97OC (207*F), the water thermoswitch turns ON to close the No.7
relay, and connects the + I and -1 terminals of the fan motor connector. The fan motor turns at low
speed (about 1,660 rpm).
2. When the coolant temperature exceeds 105OC (221 OF), the radiator thermoswitch turns ON, to close the
No.2 and No.3 relays, and connects the +2 and -2 terminals of the fan motor connector. The fan mo-
tor turns at high speed (about 2,200 rpm).
3. if the vehicle is equipped with air conditioning, the cooling fan motor operates whenever the NC switch
and the blower switch are on, regardless of the coolant temperature.
Also, when the A/C switch and the blower switch are on, the A/C retay closes to operate the additional
fan motur.

Note
l The water thermoswitch and the cooling fan reIay are normally-open switches.

Checking cooling fan operation

1. Jump across the TFA and the GND terminals of the diagnosis connector with a jumper wire.
2. Turn the ignition switch to ON and verify that the cooling fan operates smoothly.

Note
l When the water thermoswitch connector is disconnected, the cooling fan wiif not operate.

E-8
 SUPPLEMENTAL SERVICE INFORMAT1ON, THERMOSTAT E
SUPPLEMENTAL SERVICE INFURMATtON
The following points in the section are changed in comparison with Workshop Manual [Europe (1203-l 0-89F),
Australia (I 204-I 0-89f)].

Thermostat (BP DUHC Turbo only)

l Inspection
Electric cooling fan system (BP DOHC Turbo only)
l System inspection
Fan motor
l 1nspection
Water thermoswitch (BP DOHC Turbo only)
l tnspection
Radiator thermoswitch (BP DOHC Turbo only)
l Removal I Inspection I Installation
Fan relay (BP DOHC Turbo only)
l Removal ! Inspection
93GOEX-710

THERMOSTAT (BP DOHC TURBO)

INSPECTKM
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
E 3. Heat the water and check the following:
SUB-V ‘A
Initial-opening temperature:
Main: 86.5-89.5% (188--t93°F)
Sub : 83.5-86.5OC (f82--f88QF)
Full-open temperature: 100°C (212°F)
Full-open lift
Main: 8.Umm CU.31 in) min.
Sub : f.5mm (0.06 in) min.
/
E-9
E ELECTRIC COOLING FAN SYSTEM

ELECTRIC COOLING FAN SYSTEM (BP DUHC TURBO)

SYSTEM ClRCUIT
r

WITH A/C
r-- _______ ------

I
PRESSL
SWITCH
WATER
I ADDITIONAL THERMOSWfTCtl
1 FAN ABOVE 87OC (207OF): ON

RADlATOjl THERMOSWITCH
ABOVE 105*C (221 “I=): ON

SYSTEM INSPECTION
1. Jump across the test fan (TFA) terminal and the ground
(GN D) terminal of the diagnosis connector.
2. Turn the ignition switch ON and verify that the fan operates.
If the fan does not operate, inspect the cooling fan system
components and wiring harness.

8
93GOEX-719
3. Remove the radiator cap and place a thermometer in the
radiator filler neck.
4. Start the engine.
5. Verify that the fan operates when the coolant temperature
reaches approx. 97*C (207°F).
If it does, check the water thermoswitch. (Refer to page
E--i I.)

-
%
J---
-- QY- -THERMOME?ERsi-=i
--------L-
93GOEX-7 i2
E-10
FAN MOTOR, WATER THERMOSWITCH E

tNSPECTlON
Single-speed Type (For BP SOW MTX)
I. Verify that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nector.
4. Verify that current is as specified.

Current (A): 6.6 k 1

93GOEX-71:
5. If current is not within specification and/or the fan does not
turn smoothly, replace the fan motor.

Two-speed Type (Except BP SUHC MTX)

I. Verify that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectors for low-speed inspection.
4. Verify that the fan motor operates smoothly at the standard
cu vent.

93GOEX-714 Current (A): 8.8 + 10% max.

5. Connect the battery, an ammeter, and switch to the fan mo-

tor connectors for high-speed inspection.
6. Verify that the fan motor operates smoothly at the standard
current or less with the switch ON.

Current (A): 13.3 + 10% max.

7. If not as specified, replace the fan motor.

93GOEX-720

WATER THERMOSWITCH
(BP DOHC TURBO)
INSPECTlUN
I . Place the switch and a thermometer in water.
2. Heat the water gradually and check continuity of the switch
with an ohmmeter.

Coolant temperature OC (OF) 1 Contrdy

I
More than 97 (207) Yes
Less than 90 (194) NO

3. If not as specified, replace the water thermoswitch.

93GOEX.715
E RADIATOR THERMUSWlTCki

RADIATOR THERMOSWITCH (BP DUHC TURBO)

REMOVAL I INSPECTION I INSTALLATION
I. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal, referring to InstaHation Note.

7.8-13 H-m
(80-l 10 cm-kg, 69-95 h-lb)

(80-110 cm-kg,
69-95In4b)

REPLACE

1. Resonance chamber 4. Radiator thermoswitch

2. Radiator cowling mounting bolts Inspection .... ....*...... ... .. ....-. -.*,.a..- .. ... ..I. below
3. Radiator thermoswitch connector Installation Note _.,............................._. below

1NSPECTlON
1. Place the switch and a thermometer in engine oil.

Warning
l Do not heat the engine oil above 12O*C (248OF)
2. Heat the engine oil gradually and check continuity of the
switch with an ohmmeter.
Engine oil temperature “C (*F) Continuity
I
More than 105 (221) Yes
Lessthan 96 (205) No 1
t
03WEX-027
3. If not as specified, replace the radiator thermoswitch.

Installation Note
Radiator thermoswitch
Caution
l Do not use an impact wrench for installation.
1. Install the radiator thermoswitch along with a new gasket.

Tightening torque:
5.9-12 Nom (60-120 cm-kg, 52-104 in-lb)
93GOEX.721

E-12
 FAN RELAY E
FAN RELAY(BP DOHCTURBO)
REMOVAL / INSPECTION
1. Disconnect the negative battery cable.
2. Remove the fan relay.

No.2 FAN REUY

w. .. . . . .TYPE 1
@AND @ . . . TYPE 2

INSPECTDN
f . Check continuity as shown with an ohmmeter.
I
Terminal COMlLJlty
A-C No
B-D Yes

2. Apply 12V between terminals B and D.

Check for continuity between terminals A and C.
3. If not as specified, replace the fan relay.

E-13