B ENGINE

CO
SECTION
ENGINE COOLING SYSTEM C

E
CONTENTS
QG18DE SERVICE DATA AND SPECIFICATIONS (SDS) ...... 20 F
Capacity .................................................................. 20
PRECAUTIONS .......................................................... 3 Thermostat ............................................................. 20
Precautions For Liquid Gasket ................................. 3 Radiator .................................................................. 20 G
REMOVAL OF LIQUID GASKET .......................... 3
LIQUID GASKET APPLICATION PROCEDURE..... 3
PREPARATION ........................................................... 4
QR25DE
Special Service Tools ............................................... 4 H
PRECAUTIONS ........................................................ 21
OVERHEATING CAUSE ANALYSIS .......................... 5 Precautions For Liquid Gasket ............................... 21
Overheating Cause Analysis .................................... 5 REMOVAL OF LIQUID GASKET ......................... 21
COOLING SYSTEM .................................................... 7 LIQUID GASKET APPLICATION PROCEDURE... 21 I
Cooling Circuit .......................................................... 7 PREPARATION ......................................................... 22
ENGINE COOLANT .................................................... 8 Special Service Tools ............................................. 22
System Check .......................................................... 8 OVERHEATING CAUSE ANALYSIS ........................ 23 J
CHECKING COOLING SYSTEM HOSES ............ 8 Troubleshooting Chart ............................................ 23
CHECKING RESERVOIR LEVEL ......................... 8 COOLING SYSTEM .................................................. 25
CHECKING COOLING SYSTEM FOR LEAKS..... 8 Cooling Circuit ........................................................ 25
CHECKING RADIATOR ........................................ 8 K
ENGINE COOLANT .................................................. 26
CHECKING RADIATOR CAP ................................ 9 System Check ........................................................ 26
Refilling Engine Coolant ........................................... 9 CHECKING COOLING SYSTEM HOSES ........... 26
WATER PUMP .......................................................... 10 CHECKING RESERVOIR LEVEL ....................... 26 L
Removal and Installation ........................................ 10 CHECKING COOLING SYSTEM FOR LEAKS ... 26
Inspection ................................................................11 CHECKING RADIATOR ...................................... 26
THERMOSTAT AND THERMOSTAT HOUSING ...... 12 CHECKING RADIATOR CAP .............................. 27 M
Removal and Installation ........................................ 12 Refilling Engine Coolant ......................................... 27
REMOVAL ........................................................... 12 WATER PUMP .......................................................... 28
INSPECTION AFTER REMOVAL ....................... 12 Removal and Installation ........................................ 28
INSTALLATION ................................................... 13 REMOVAL ........................................................... 28
RADIATOR ................................................................ 14 INSPECTION AFTER REMOVAL ....................... 29
Removal and Installation ........................................ 14 INSTALLATION ................................................... 29
REMOVAL ........................................................... 14 INSPECTION AFTER INSTALLATION ................ 29
INSTALLATION ................................................... 14 THERMOSTAT AND THERMOSTAT HOUSING ...... 30
Disassembly and Assembly ................................... 15 Removal and Installation ........................................ 30
PREPARATION .................................................. 15 REMOVAL ........................................................... 30
DISASSEMBLY ................................................... 15 INSPECTION AFTER REMOVAL ....................... 31
ASSEMBLY ......................................................... 16 INSTALLATION ................................................... 31
Inspection ............................................................... 18 RADIATOR ................................................................ 32
COOLING FAN ......................................................... 19 Removal and Installation ........................................ 32
Disassembly and Assembly Radiator Cooling Fan... 19 REMOVAL ........................................................... 32
DISASSEMBLY ................................................... 19 INSTALLATION ................................................... 32
ASSEMBLY ......................................................... 19

CO-1
 Disassembly and Assembly .................................... 33 SERVICE DATA AND SPECIFICATIONS (SDS) ......38
PREPARATION ................................................... 33 Capacity ..................................................................38
DISASSEMBLY ................................................... 33 Thermostat ..............................................................38
ASSEMBLY ......................................................... 34 Water Control Valve ................................................38
Inspection ............................................................... 36 Radiator ..................................................................38
COOLING FAN .......................................................... 37
Disassembly and Assembly .................................... 37
DISASSEMBLY ................................................... 37
ASSEMBLY ......................................................... 37

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

REMOVAL OF LIQUID GASKET

● 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
● 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
● 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-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
PBIC0003E

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

L
EMA0622D

M
● As for the bolt holes, normally apply the sealant inside the holes.
Occasionally, it should be applied outside the holes.
● Within five minutes of sealant application, install the mating
component.
● If the sealant protrudes, wipe it off immediately.
● Do not retighten after the installation.
● 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
Overheating Cause Analysis 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 — — —
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

CO-5
 OVERHEATING CAUSE ANALYSIS
[QG18DE]
Symptom Check items
High engine RPM under no
load
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
Over heating engine Overload on engine
Powertrain system mal-
function
Except cool- Installed improper size
ing system wheels and tires —
parts mal-
Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere
Blocked radiator grille
Blocked or restricted air __ Mud, debris, or paper clog-
flow Blocked radiator — ging

Blocked condenser
—
Installed large fog lamp

CO-6
 COOLING SYSTEM
[QG18DE]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS00CH4

CO

WBIA0132E

CO-7
 ENGINE COOLANT
[QG18DE]
ENGINE COOLANT PFP:KQ100

System Check EBS00CH5

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

SMA412B

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system using
Tool.
Testing pressure : 157 kPa (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.
SLC756A

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows:
● Be careful not to bend or damage the radiator fins.
● 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.
● Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 300 mm (11.8
in).

CO-8
 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. A

CHECKING RADIATOR CAP

● To check radiator cap, apply pressure to cap using Tool. CO
Radiator cap relief pressure
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
C
Limit : 59 kPa (0.6 kg/cm2 , 9 psi)

SLC755A
E
● Pull the negative pressure valve to open it.
● Check that it closes completely when released.
F

H
SMA967B

Refilling Engine Coolant EBS00CH6

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

CO-9
 WATER PUMP
[QG18DE]
WATER PUMP PFP:21020

Removal and Installation EBS00CH7

WLC017

CAUTION:
● When removing water pump assembly, be careful not to get coolant on drive belt.
● Water pump cannot be disassembled and should be replaced as a unit.
● After installing water pump, check for leaks using radiator cap tester. Refer to CO-8, "CHECKING
COOLING SYSTEM FOR LEAKS" .
1. Drain engine coolant.
Refer to MA-16, "DRAINING ENGINE COOLANT" .

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-10
 WATER PUMP
[QG18DE]
7. Remove the water pump bolts.
8. Remove the water pump. A
● Remove liquid gasket from water pump and mating surface of
cylinder block using a scraper.
9. Installation is in the reverse order of removal. CO
● When applying liquid gasket to mating surface of water pump,
use Genuine Anaerobic Liquid Gasket or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND C
SEALANTS" .
● When filling radiator with coolant, refer to MA-17, "REFILLING SEM859F
ENGINE COOLANT" . D
● When installing drive belts, refer to MA-16, "Checking Drive Belts" .

Inspection EBS00CH8
E
1. Rotate water pump shaft, replace the water pump as necessary.
● Check body assembly and vane for rust or corrosion.
● Check for rough operation due to excessive end play. F

H
SEM860F

CO-11
 THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
THERMOSTAT AND THERMOSTAT HOUSING PFP:21200

Removal and Installation EBS00CH9

WBIA0134E

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
CAUTION:
Perform when the engine is cold.
CAUTION:
Be careful not to spill coolant over the engine compartment. Use a rag to absorb any spilled coolant.
REMOVAL
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.
INSPECTION AFTER REMOVAL
● Place a string so that it is caught in the valve of the thermostat
(or water control valve) and suspend it in boiling water. It must
be fully immersed in the water.
● The valve opening temperature is the temperature at which the
valve plate begins to rise from the top plate causing the thermo-
stat to fall off of the string.
● Continue heating the water and thermostat to check the valve lift
(the full-open valve lift distance).
NOTE:
The valve lift standard temperature for the thermostat (or water
control valve) is the reference value. SLC252B

● After checking the valve lift, lower the water temperature and check the valve closing temperature.
Standard Values
Valve opening temperature 76.5°C (170°F)
More than 9 mm/90°C
Valve lift
(0.35 in/194°F)
Valve closing temperature 71.5°C (161°F)

CO-12
 THERMOSTAT AND THERMOSTAT HOUSING
[QG18DE]
INSTALLATION
1. Installation is in the reverse order of removal, paying attention to the following: A
● Before installing the thermostat, make sure the gum ring is
properly seated around the thermostat.
CO

D
SEM862F

E
● Install thermostat with jiggle valve or air bleeder at upper side.

H
SEM863F

● Refill engine coolant after installation. Run engine for a few minutes, and check for any coolant leaks.
Refer to MA-17, "REFILLING ENGINE COOLANT" I

CO-13
 RADIATOR
[QG18DE]
RADIATOR PFP:21400

Removal and Installation EBS00CHB

WBIA0315E

1. Reservoir tank 2. Reservoir tank bracket 3. Radiator cap

4. Mounting bracket 5. Upper radiator hose 6. Cooling fans
7. Radiator drain plug 8. Mounting rubber 9. Oil cooler hose (A/T models)
10. Radiator 11. Lower radiator hose

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns can occur from high pressure
coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly push down and turn it a
quarter of a turn to allow the built-up pressure to escape. Carefully remove the cap by pushing down
and turning it the rest of the way.
REMOVAL
1. Drain engine coolant. Refer to MA-16, "DRAINING ENGINE COOLANT" .
2. Remove the air duct and air cleaner assembly.
3. Disconnect the A/T oil cooler hoses (if equipped) and install a blind plug in the hoses to prevent A/T oil
loss.
4. Disconnect the upper and lower radiator hoses and mounting bracket.
5. Remove the radiator and radiator fan assembly as one unit.
CAUTION:
Do not damage or scratch the radiator core when removing.
INSTALLATION
● Installation is in the reverse order of removal.

CO-14
 RADIATOR
[QG18DE]
Disassembly and Assembly EBS00CHC

CO

WBIA0316E

1. Upper tank 2. Sealing rubber 3. Core G

4. Oil cooler securing nut 5. O-ring 6. Oil cooler
7. Lower tank 8. Sealing rubber
H
PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A.
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) I
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in).
J
3. Adjust dimension H′′ with the spacer, if necessary.

SLC655CB

DISASSEMBLY L
1. Remove tank using Tool.

SLC903-A

CO-15
 RADIATOR
[QG18DE]
● Grip the crimped edge and bend it upwards so that Tool slips
off.
CAUTION:
Do not bend excessively.

SLC893

● In areas where Tool cannot be used, use a screwdriver to

bend the edge up.
CAUTION:
Be careful not to damage tank.

SLC930

2. Make sure the edge stands straight up.

3. Remove oil cooler from tank (A/T model only).

SLC931

ASSEMBLY
1. Install oil cooler (A/T model only).

WBIA0317E

CO-16
 RADIATOR
[QG18DE]
2. Clean contact portion of tank.
A

CO

SLC932

D
3. Install sealing rubber.
NOTE:
Push it in with fingers. E
CAUTION:
Be careful not to twist sealing rubber.
F

G
SLC917A

4. Crimp the tank rim in a specified sequence using Tool. H

K
SLC904-A

SLC896

● Use pliers in the locations where the Tool cannot be used.

SLC897

CO-17
 RADIATOR
[QG18DE]

5. Make sure that the tank rim is completely crimped down.

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
6. Check for any coolant leakage. Refer to CO-8, "CHECKING
COOLING SYSTEM FOR LEAKS" .

SLC554A

Inspection EBS00CHD

1. Apply pressure using Tool.

Specified pressure value : 157 kPa (1.6 kg/cm2 , 23
psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well (A/T model only).

SLC933-A

2. Check for leaks in dip tank.

SLC934

CO-18
 COOLING FAN
[QG18DE]
COOLING FAN PFP:21486
A
Disassembly and Assembly Radiator Cooling Fan EBS00CHE

CO

WBIA0319E

1. Cooling fan motors 2. Cooling fan shroud 3. Cooling fan blades J

DISASSEMBLY
1. Remove the radiator and cooling fan assembly. Refer to CO-14, "Removal" .
K
2. Remove the cooling fan shroud assembly from the radiator.
3. Remove the cooling fan blades from the shroud.
4. Remove cooling fan motors from the shroud. L
ASSEMBLY
● Assembly is in the reverse order of disassembly.
M

CO-19
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QG18DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Capacity EBS00GJS

Unit: (US qt, Imp qt)

A/T 6.6 (7, 5 7/8)
Coolant capacity with reservoir tank (MAX level)
M/T 6.7 (7 1/8, 5 7/8)

Thermostat EBS00CHF

Valve opening temperature 76.5°C (170°F)

Valve lift More than 9 mm/90°C (0.35 in/194°F)
Valve closing temperature 71.5°C (161°F)

Radiator EBS00CHG

Unit: kPa (kg/cm2 , psi)

Standard 78 - 98 (0.8 - 1.0, 11 - 14)
Cap relief pressure
Limit 59 (0.6, 9)
Leakage test pressure 157 (1.6, 23)

CO-20
 PRECAUTIONS
[QR25DE]
PRECAUTIONS PFP:00001
A
Precautions For Liquid Gasket EBS00CHH

REMOVAL OF LIQUID GASKET

● 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
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the sealant 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
● 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-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
PBIC0003E

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

L
EMA0622D

M
● As for the bolt holes, normally apply the sealant inside the holes.
Occasionally, it should be applied outside the holes.
● Within five minutes of sealant application, install the mating
component.
● If the sealant protrudes, wipe it off immediately.
● Do not retighten after the installation.
● 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-21
 PREPARATION
[QR25DE]
PREPARATION PFP:00002

Special Service Tools EBS00CHI

The actual shapes of Kent-Moore tools may differ from those of special tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
WS39930000 Pressing the tube of liquid gasket
( — )
Tube presser

S-NT052

EG17650301 Adapting radiator cap tester to radiator filler

(J33984-A) neck
Radiator cap tester adapter a: 28 (1.10) diameter
b: 31.4 (1.236) diameter
c: 41.3 (1.626) diameter
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-22
 OVERHEATING CAUSE ANALYSIS
[QR25DE]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS00CHJ

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- Fan blades —
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

CO-23
 OVERHEATING CAUSE ANALYSIS
[QR25DE]
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
Except cool- Installed improper size
ing system wheels and tires —
parts mal-
Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere
Blocked radiator grille
Blocked or restricted air — Mud, debris, or paper clog-
flow Blocked radiator — ging

Blocked condenser
—
Installed large fog lamp

CO-24
 COOLING SYSTEM
[QR25DE]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS00CHK

CO

PBIC0234E

PBIC0280E

CO-25
 ENGINE COOLANT
[QR25DE]
ENGINE COOLANT PFP:KQ100

System Check EBS00EYS

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

SMA412B

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system using
Tool.
Testing pressure : 157 kPa (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.
SLC756A

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows:
● Be careful not to bend or damage the radiator fins.
● 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 is flowing off the radiator.
4. Blow air into the back side of radiator core vertically downward.
● Use compressed air lower than 490 kPa (5 kg/cm2 , 71psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CO-26
 ENGINE COOLANT
[QR25DE]
6. Check for leaks.
A
CHECKING RADIATOR CAP
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.
● Check that there are no abnormalities in the opening and closing conditions of the negative-pressure CO
valve.
● Pull the negative pressure valve to open it.
● Check that it closes completely when released. C

SMA967B

F
● Check radiator cap relief pressure using Tool.
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
G
Limit : 59 kPa (0.6 kg/cm2 , 9 psi)
● When connecting the radiator cap to the tester, apply water to
the cap seal surface. H
● Replace the radiator cap if there is an abnormality in the nega-
tive-pressure valve, or if the open-valve pressure is outside of
the standard values. I
SLC135B

Refilling Engine Coolant EBS00EYT

J
Changing the engine coolant is part of the required maintenance of the engine. Refer to MA-23, "Changing
Engine Coolant" .
K

CO-27
 WATER PUMP
[QR25DE]
WATER PUMP PFP:21020

Removal and Installation EBS00CHN

KBIA0154E

1. Water pump 2. Gasket 3. Water pump housing

4. Water pipe

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Water Pump
1. Drain the engine coolant. Refer to MA-23, "DRAINING ENGINE COOLANT" .
CAUTION:
Perform when the engine is cold.
2. Remove the generator. Refer to SC-32, "Removal" .
3. Remove the water pump.
● Coolant will leak from the cylinder block, have a drain pan in position.

CAUTION:
● Handle the water pump vane so that it does not contact any other parts.

● The water pump cannot be disassembled and should be replaced as a unit.

4. Remove the water pipe mounting bolts.

5. Remove the water pump housing from the engine block. Use a new gasket for installation.
Water Pipe
1. Remove the water pump.
2. Remove the exhaust manifold. Refer to EX-3, "Removal and Installation" .
3. Remove the water pipe from the thermostat housing.

CO-28
 WATER PUMP
[QR25DE]
INSPECTION AFTER REMOVAL
● Visually check that there is no significant dirt or rust on the water A
pump body and vane.
● Check that there is no play when rotating the vane shaft, and
that it turns smoothly when rotated by hand. CO
● If necessary, replace the water pump as an assembly.

KBIA0155E
D

INSTALLATION
Installation is in the reverse order of removal. E
NOTE:
When inserting the water pipe end into the thermostat housing, apply coolant to the O-ring seal and install
immediately.
F
INSPECTION AFTER INSTALLATION
After installing the water pump and pipe, check for leaks using the radiator cap tester. Refer to CO-26,
"CHECKING RADIATOR" . G

CO-29
 THERMOSTAT AND THERMOSTAT HOUSING
[QR25DE]
THERMOSTAT AND THERMOSTAT HOUSING PFP:21200

Removal and Installation EBS00CHO

WBIA0010E

1. Thermostat 2. Water inlet housing 3. Water control valve

4. Water outlet housing 5. Heater hose 6. Water temperature sensor
7. Heater pipe 8. Throttle body coolant inlet 9. Throttle body coolant outlet

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
CAUTION:
Perform when the engine is cold.
CAUTION:
Be careful not to spill coolant over the engine compartment. Use a rag to absorb any spilled coolant.
REMOVAL
Thermostat
1. Drain engine coolant. Refer to MA-23, "DRAINING ENGINE COOLANT" .
2. Remove the lower radiator hose from the water inlet housing.
3. Remove the water inlet housing.
4. Remove the thermostat.
Water Control Valve
1. Drain engine coolant. Refer to MA-23, "DRAINING ENGINE COOLANT" .
2. Remove the upper radiator hose, heater pipe, and heater hose.
3. Remove the water outlet housing.

CO-30
 THERMOSTAT AND THERMOSTAT HOUSING
[QR25DE]
4. Remove the water control valve.
A
INSPECTION AFTER REMOVAL
● Place a string so that it is caught in the valve of the thermostat
(or water control valve) and suspend it in boiling water. It must
be fully immersed in the water. CO
● The valve opening temperature is the temperature at which the
valve plate begins to rise from the top plate causing the thermo-
stat to fall off of the string. C
● Continue heating the water and thermostat to check valve lift
(the full-open valve lift distance).
NOTE: D
The valve lift standard temperature for the thermostat (or water
control valve) is the reference value. SLC252B

● After checking the valve lift, lower the water temperature and check the valve closing temperature. E
Standard Values
Component Thermostat Water control valve
F
Valve opening temperature 80.5 - 83.5°C (177 - 182°F) 93.5 - 96.5°C (200 - 206°F)
More than 8 mm/95°C More than 8 mm/108°C
Valve lift
(0.315 in/203°F) (0.315 in/226° F) G
Valve closing temperature 77°C (171°F) 90°C (194° F)

INSTALLATION
H
● Installation is in the reverse order of removal.
Thermostat and Water Control Valve
● Install the thermostat and water control valve with the whole cir- I
cumference of each flange fitting securely inside the rubber ring.
(The example in the figure shown is the thermostat.)
J

PBIC0157E L

● Install the thermostat with the jiggle valve facing upwards. (The
position deviation may be within the range of ±10°.) M
● Install the water control valve with the up-mark facing up and the
frame center part facing upwards. The position deviation may be
within the range of ±10° of vertical.

PBIC0158E

Heater Pipe
● Apply clean coolant to the heater pipe O-ring, and immediately install the heater pipe into the installation
holes.

CO-31
 RADIATOR
[QR25DE]
RADIATOR PFP:21400

Removal and Installation EBS00CHP

WBIA0322E

1. Radiator 2. Bracket 3. Mounting rubber

4. A/T oil cooler hose (if equipped) 5. Radiator hose (lower) 6. Cooling fan assembly
7. Reservoir tank 8. Radiator hose (upper) 9. Radiator cap
10. Drain plug

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly push down and turn it a
quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing down and turn-
ing it three-quarters around.
REMOVAL
1. Drain the engine coolant. Refer to MA-23, "DRAINING ENGINE COOLANT" .
2. Remove the air duct with air cleaner assembly. Refer to EM-101, "Removal and Installation" .
3. Disconnect A/T oil cooler hoses (if equipped).
● Install a blind plug to avoid leakage of A/T oil.

4. Disconnect the radiator upper hose, lower hose, and mounting bracket.
5. Remove the radiator and cooling fan assembly
CAUTION:
● Do not damage or scratch radiator core when removing.
INSTALLATION
Installation is in the reverse order of removal.
● After installation, run the engine until it reaches full operating temperature and check for any cooling sys-
tem leaks. Repair any leaks as necessary.

CO-32
 RADIATOR
[QR25DE]
Disassembly and Assembly EBS00CHQ

CO

WBIA0316E

1. Upper tank 2. Sealing rubber 3. Core G

4. Oil cooler securing nut 5. O-ring 6. Oil cooler
7. Lower tank 8. Sealing rubber
H
PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A.
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) I
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in).
J
3. Adjust dimension H′′ with the spacer, if necessary.

SLC655C

DISASSEMBLY L
1. Remove tank using Tool.

SLC903

CO-33
 RADIATOR
[QR25DE]
● Grip the crimped edge and bend it upwards so that the Tool
slips off.
CAUTION:
Do not bend excessively.

SLC893

● In areas where Tool cannot be used, use a screwdriver to bend

the edge up.
CAUTION:
Be careful not to damage tank.

SLC930

2. Make sure the edge stands straight up.

3. Remove oil cooler from tank (A/T model only).

SLC931

ASSEMBLY
1. Install oil cooler (A/T model only).

WBIA0317E

CO-34
 RADIATOR
[QR25DE]
2. Clean contact portion of tank.
A

CO

SLC932

D
3. Install sealing rubber.
NOTE:
Push it in with fingers. E
CAUTION:
Be careful not to twist sealing rubber.
F

G
SLC917A

4. Crimp tank in specified sequence using Tool. H

K
SLC904

SLC896

● Use pliers in the locations where Tool cannot be used.

SLC897

CO-35
 RADIATOR
[QR25DE]

5. Make sure that the rim is completely crimped down.

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
● Refer to CO-26, "CHECKING COOLING SYSTEM FOR
LEAKS" .

SLC554A

Inspection EBS00CHR

1. Apply pressure using Tool.

Specified pres- : 157 kPa (1.6 kg/cm2 , 23 psi)
sure value
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well (A/T model only).

SLC933

2. Check for leaks in dip tank.

SLC934

CO-36
 COOLING FAN
[QR25DE]
COOLING FAN PFP:21060
A
Disassembly and Assembly EBS00CHS

CO

WBIA0323E

1. Cooling fan motor 2. Insulator 3. Cooling fan shroud J

4. Cooling fan blade

DISASSEMBLY
K
1. Remove the radiator and cooling fan assembly. Refer to CO-32, "REMOVAL" .
2. Remove the cooling fan shroud from the radiator.
3. Remove the cooling fan blades from the cooling fan motors. L
4. Remove the insulator.
5. Remove the cooling fan motors from the fan shroud.
ASSEMBLY M
● Assembly is in the reverse order of disassembly.

CO-37
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QR25DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Capacity EBS00CHT

Unit: (US qt, Imp qt)

A/T 6.7 (7 1/8, 5 7/8)
Coolant capacity with reservoir tank (MAX level)
M/T 6.8 (7 3/16, 6)

Thermostat EBS00CHU

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Valve lift More than 8 mm/95°C (0.315 in/203°F)
Valve closing temperature 77°C (171°F)

Water Control Valve EBS00CHV

Valve opening temperature 93.5 - 96.5°C (200 - 206°F)

Valve lift More than 8 mm/108°C (0.315 in/226°F)
Valve closing temperature 90°C (194°F)

Radiator EBS00CHW

Unit: kPa (kg/cm2 , psi)

Standard 78- 98 (0.8 -1.0, 11-14)
Cap relief pressure
Limit 59 (0.6, 9)
Leakage test pressure 157 (1.6, 23)

CO-38