2.
Remove the drive belt(A).
Drain engine coolant.
System is under high pressure when the engine is hot.
To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
Remove the drive belt(A).
Remove the water pump pulley(A).
Remove the water pump(A).
Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
Drain engine coolant so that its level would be under the thermostat height.
Remove the water inlet fitting(A), gasket and thermostat(B).
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the radiator upper hose(A) and the breather hose(B).
Remove the radiator lower hose(A).
Disconnect the fan motor connector(A).
Remove the blower assembly(A) for cooling module.
Disconnect the ATF oil cooler hoses(A).
Remove the radiator upper bracket(A), then pull up the cooling module.
After pulling back the condenser fixing bracket(A), remove the radiator assembly.
Drain engine coolant.
Remove the air cleaner assemlby.
Disconnect the air cleaner hose(A) and breather hose(B).
Remove the accelerator cable(C).
Disconnect the powertrain control module(PCM) connector(D).
Remove the air cleanerassemlby(E).
Remove the engine coolant hose(A).
Remove the water temperature control assemlby(A).
To install, reverse the removal orders.
Clean the surface of the water temperature control assembly before installing.
Install the water pump.
Install the water pump(A) and a new gasket with the bolts.
Tighten the bolts with the order blow.
Install the water pump pulley(A) with the four bolts.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Tighten the bolts diagonally.
Install the drive belts.
Fill with engine coolant.
Start engine and check for leaks.
Recheck engine coolant level.
Place the thermostat in the block.
Install the thermostat(B) with the jiggle valve upward.
Install a new gasket to the thermostat(B).
Install the water inlet fitting(A).
Tightening torque :
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Fill with engine coolant.
Start engine and check for leaks.
Install the radiator.
Install the radiator upper bracket(A).
Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
Install the ATF(Automatic Transaxle Fluid) oil cooler hoses(A).
Connect the fan motor connector(A).
Install the radiator lower hose(A).
Connect the radiator upper hose(A) and the breather hose(B).
Fill with engine coolant.
Start engine and check for leaks.
Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.
A small amount of “weeping” from the bleed hole is normal.
Immerse the thermostat in water and gradually heat the water.
Check the valve opening temperature.
Valve opening temperature : 82±1.5°C (179.6±2.7˚F)
Full opening temperature : 95°C (203˚F)
If the valve opening temperature is not as specified, replace the thermostat.
Check the valve lift.
Valve lift : 8mm(0.3in) or more at 95°C (203˚F)
If the valve lift is not as specified, replace the thermostat.
Disconnect the cooling fan motor connector.
Check that the radiator fan rotates when battery voltage is applied between the terminals.
Cooing fan inspection | Cooling fan motor connector | Action | |||
1 | 2 | 3 | |||
Battery | + | O | High speed | ||
- | O | ||||
Battery | + | O | Low speed | ||
- | O | ||||
Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of the paint. If any coolant spills, rinse it off immediately.
Remove the radiator cap.
Loosen the drain plug, and drain coolant.
Tighten the radiator drain plug securely.
Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant reservoir tank to the MAX mark with coolant mixture.(coolant 5 : water 5)
Fill coolant mixture into the radiator to the base of filler neck. Gently squeeze the upper/lower hoses of radiator so as to bleed air easily.
Mix the recommended antifreeze with an equal amount of water in a clean container.
Use only genuine antifreeze/coolant.
For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum. Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
Coolant concentration greater then 60% will impair cooling efficiency and are not recommended.
Do not mix different brands of antifreeze/coolants.
Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
Start engine and allow coolant mixture to circulate.
When the cooling fan operates and coolant circulates, refill coolant through the radiator filler neck.
Repeat 6 until the cooling fan 3~5 times and bleed air sufficiently out of the cooling system.
Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
Run the vehicle under idle until the cooling fan operates 2~3 times.
Stop the engine and allow coolant to cool.
Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system.
Recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant.
Coolant capacity :
5.8 ~ 5.9 liters(6.13 ~ 6.23 US qt, 5.10 ~ 5.19 lmp qt)
Remove the radiator cap, wet its seal with engine coolant, then install it on a pressure tester.
Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Check for a drop in pressure.
If the pressure drops, replace the cap.
Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester.
Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
Inspect for engine coolant leaks and a drop in pressure.
Remove the tester and reinstall the radiator cap.
Check for engine oil in the coolant and/or coolant in the engine oil.
