E

COOLINGSYSTEM
fNDEX................... ..,'.'E- 2
ouTLlNE,.............. ...... E- 3
E- 3
spEctFtcATloNS....,......-.......................
TROUBLESHOOTING E- 3
GU|DE....................,.
ENGINECOOLANT. ...... E- 4
pREPARAT|ON.......................................
E- 4
E- 4
rNspEcTtoN............-.........-..................

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REP1ACEMENT..........,........................... E- 5
RADTATOR CAP..... ...... E- 6
PREPARAT|ON.......................................E- 6
E- 6
rNSPECTrON...................,...........,..........
RADfATOR ............ ......E- 7
REMOVAL / TNSTALLATION .............,........E- 7
E- 7
rNSPECT|ON............,.............................
THERMOSTAT....... ..'... E- 8
REMOVAL / INSTALLATION .......,............'.E- 8
E- 9
tNSPECTrON..........,...............................
WATERPUMP....... ...... E-10
REMOVAL / rNSTAI1AT|ON ......................E-i0
ELECTRICCOOLING FAN SYSTEM ....'....... E-l t
SYSTEM c|Rcu1r..................""""""""" E-1I
sysrEM tNSPECT|ON.......................,...... E-l I
FAN MOTOR.......,.. ...'.' E-12
tNSpECT|ON E-12
..........................................
E-l2
REPLACEI,|ENT......................................
warER THEBMOSWITCH E-l3
..........................
REMOVAL / TNSTALLATION ...........-,.........E-i3
lNSPEcrloN """""" E-13
FAN RELAY........... ......E-i4
REMOVAL / lNSTALLAT|ON E-l4
.....-................
lNSPEcrloN..."""""""""""""""""""' E-l4
E INDEX
INDEX

CONNECTOF

ENGINECOOLANTTOTALCAPACITY:
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5.0(5.3,4..r) 6.0 (6,3,5,3)

1. Enginecoolant 6. Electriccoolingfan system

I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e. .-. .4. . . . . .
.E System c i r c u i t . . . . . . . . . . . . ... . . .p a g eE - 1 1
R e p | a c e m e n t . . . . . . . . . . . . . . . .p.a. .g. eE - 5 S y s t e m i n s p e c r i o n . . . . . . . . .p. .a.g. .e. .E. - 1 1
2. Radiatorcap 7. Fanmotor
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e
.E
. .-. .6. . . . . . l n s p e c i i o n . . . . . . . . . . . . . . . . . . .p. .a. .S. .eE. .-.1. .?. . . . .
3. Radiator 8 e p 1 a c e m e n t . . . . . . . . . . . . . . .p. .a.g. .e.E. .-.1. 2 ..
Removal / Insla|ation.................. page E- 7 B. Water thermoswitch
4. Thermostat Removal / Insta||atron.................. pageE - 13
Removal / Instal|ation.................. pageE- 8 9. Fanrelay
5. Water pump Removal / Installation............... . pageE-14
Removal / Instaj|ation.................. pageE-10

E-2
 OUTLINE.TBOUBLESHOOTING
GUIDE E
OUTLINE
SPECIFICATIONS
Enginemodel B3
|rem
Coolingsyslem iorcedc rculation
Waier<,ooled,
Coolanlcapacily lite6 (US qt, lmp qt) [4IX 5.0(s.3 4.4) ATX.6O(6.3.s.3)
Centnrugal
bell-driven
Unlliedmechanicalseal
Tvpe
Openinglemperature 'C fD 86.5 89.5 (187-193)

Full-open
temperature 'C fR 1OO\212)

Fifopen ltt mm (in) 8.5 (0.335)or more

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corugatediin
Radiator
Cap valveopeningpressJre hPa (kg/cm?.ps, 74-103(0.75-r.05.
1r-r5)
l4olorcurrenl A 6.6+1

Coolinglan

Outerd ameterol blade mm (in) 300(rr.9)

TROUBLESHOOTING
GUIDE
Problem Possible Cau3e Remedy Page
Overhealin9 Coolantlevel insuiticient E-4
Coolantleakage
Radlatorfinsclogged Clean
Badialorcap malfunction E-6
Cooiingfan malfunclion E-11
Thermogalmalfunction E-8
Walerpassageclogg€d Clean E-5
Waterpumpmalfunction E-10
Coro€lon E-5

E-3
 ENGINECOOLANT
ENGINECOOLANT
PREPABATION
ssT

49 DO150A0 49 D015002

49 DO15040)

INSPECTION
Waming
. Nevei removethe radiatorcap while lhe enginei6
hot,
. W;D a thick clolh aroundthe cap when removinglt'

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. wh;n removingthe radiatorcap, loosen ltslowly
to the tirst stotuntllthe Pressureln the radlalorls
released, and then remove il.
muoEx.oo6

CoolantLevel (Enginecold)
1. Venlythatthe'coolantlevelis nearthe radiatorirllerneck
2. Veritvthatthe coolantlevelIn lhe coolantreservioris be
weeh the FULLand LoW marks
3. Add coolantit necessary

CoolantOuality
1 Verffvthatthie is no buildupof rustor scalearoundthe
radiatorcap or radiatorfillerneck
2. Veritvthat coolantis lree of oil Replacethe coolantif
necessary.

CoglantLeakage
1.connecta radlalortester(commercially availade)andthe
SSTto the radiatorfillerneck,
z. AppV tO3 kPa (1.05 kg/cm', 15 psi) pressureto the
svstem.
3. V'erifvthatthe pressureis held
checklor coolantleakage
4. lt noi as specified,

E-4
 ENGINECOOLANT E
CoolantProtection
Caution
. Do not uae alcohol- or methanol-basedcoolant.
. Use only soft (demineralized)water In the coolant
mixture.
1. Measure thecoolant temperature andspecfiicgravitywith
a thermometer anda hydrometer.
2. Determine thecoolantproreclion by referring
to thegraphI
s. iili" loor"n, prot""tionis norproper,add w"te, o, "oolanl.E

Antlfreeze solutlon mlxture percentage

Gravityat
Coobrn pdeclion 2o.c (68.0
Coolant
Above -16oC ( 3oR 65 35 1054
Above -26oC {-1soR 45 1066
Above-4ooo i-40on '1o78

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45
CCfF)
COOL^NTTEMPERATUFE

REPLACEMENT
ol EoEx@7
Warnlng
. Neveropen lhe radialor cap while the engine ls hot.
. Wrapa thlckclolh aroundthccap when loosening.
. Whenremovinglhe radiatorcap, loosen it slowly
to the tirst stop unlll the presaure in the radiator is
released. and then remove it.
. Use cautlonwhen draininghol coolant.

Cautlon
. Do nol use alcohol-or methanol-based coolant.
. Useonly sotl (demineralized) water ln the coolant
mixture.
. Befors looseningthe radlalor draln plug, verity thal
lhe radlatgrdrain hose taces slraight down.
1. Bemovethe radiatorcapandloosen$e drainplugby hand
(MTE or by a wrench(ATX).
2. Drainthe coolanlinloa suilablecontaner.
3. Flushthecoolingsystemwithwateruntilalltracesof color
are goneithenletthe systemdraincompletely.
4. Insiallthe drainplug.
5. Fillwiththe properamountandmixtureof ethyleneglycol
basedcoolantby referringto the tableabove.
Coolanicapaclty lilers(USqi, lmpql)
B3
i\,ITX AIX
5.0 (5.3,4.4) 6.016.3,
s.3)

6. Runtheenginewiththeradiator capremoveduntiltheup
per radiatorhoseis hot.
7. Withthe engineidling,add coolantto the radiatoruntilit
reachesthe bottomot the filler neck.
8. Installthe radiatorcap.

E-5
E RADIATORCAP
RADIATORCAP
PREPARATION
ssT
49 DO150A0 49 D015003
AdaplerB
49 D0150A0)

INSPECTION
Radiato. Cap Valve
1. Removeforeignmaterial (suchas waterresidue) frombe
tweenthe radiatorcap valve and the valveseat.
2. Attachthe radiatorcapto a radiatorcaptester(commer'
withtheSST.Applypressure
ciallvavailable) gradually
to
74-103 kPa (0.?5-1.05 kg/cm" 11-'15 psl)

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3. WaitaboutlO aecgnds.Veritythatthe pressurehasnot
decreased.
4. Feplacethe radiatorcap il necessary

N€gative Pressurc valve

1. Pullthe negativepressurevalve10openI VerifyIhat it
closescomDletelv whenreleased
2. Checkior damag;onthecontactsurfaces andforcracked
-,-'-_ \\
' or deformedsealPacking.
kk=fiK"DlN"
\{ ,l\\\//rIA\ ,--A\,\
f-
3. ReDlace the radiator€p if necessary'
-/ \,\
/\\\\}1

\lt\v2liK\
'ii::\!@=-

E-6
 RADIATOR
RADIATOR
REMOVAL/ INSTALLATION
Caution
. Eetore loosening the radiator drain plug, verlty lhat the radiator d.ain hose tac€s straight down,
. Poallionthe hose damp in the originallocalionon the hose, and squeezethe clamp lightly
with large pliers to ensure a good tit.
1 Disconnecl lhe negatrvebatterycable.
2. Drainthe enginecoolant.
3. Removein the ordershownin the figure.
4. lnstallin the reverseoroerol removal
r*n {3o-1 ro cfrrg, 6F95 hrb)

1.Cooling fan connector 5. Radiatorbracket

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2. Coolantreservoirhose 6. Radiator
3. Radialorhose I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .p. .a. g
. .e.E. . .7. . . . . . .
4. Oilcoolerhose(ATX) 7-Coolingfan and radiatorcowlingassembly
INSPECTION
Checkfor thetollowing and repairor replaceas necessary.
1. Cracks,damage,and waterleakage.
2. Bentlins(repairwitha screwdriver).
3. Distonedor bentradiatorinlet.
Sleps Atter Installation
1. Fillthe radiator
withthe specifiedamountandtypeof en-
ginecoolant.(Referto pageE-4.)
2. Connectthe negativebatterycable.
3. Startthe engineand checkfor leaks.

E-7
 THERMOSTAT
THERMOSTAT
REi'OVAL/ INSTALLATION
Caution
. Betore loosening the radlator drain ptug, verlty that the radiatordrain ho€elace€ slraighl {oll.
. Positionthe hose clamp In the originil locatlonon the hose' and squeezethe clamp lightly
with large pliers to ensure a good tll.
L Disconnect the negatlvebatterycable
2. Drainthe enginecoolant-
3. Removein the ordershownin the figure.
4. Installin the reverseorderof removal.

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(r.9-2.6 n-kg, ra-rg ftlb,

1.Waterthermoswitch connector 5. Thermostat

2. Upperradiatorhose pageE-9
Inspection.....................................
3. Thermostatcover Installation pageE-g
Note........................,...
4. Thermostatgasket
pageE-g
Note............................
Installation

E-8
 THERMOSTAT
INSPECTION
'1.Visuallycheckthat
the thermostat
valveis airtaght.
2. Placethe thermostatand a thermometerin water.
3. Heatthe waterand checkthe following:
B3
Openinglempe.ature "C (.D 86.5-89.5 (187-193)
FuI'opentemperalure oC (oD lOO1212)
Full-openlilt mm (in) 8.5 (0.335)
or more

Installation Note
Thermostat
Installthe intothecylinderheadwiththejigglepin
thermostat
at the top.

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Thermoslal gasket
Installa newgasketwiththe sealingringfacingthe cylinder
neao.

0rEoE(.o16

Steps Atter Installation

1. Fillthe radiatorwiththe specifred
amountandtype of enginecoolant.(Referto pageE-5.)
z. Uonnectthe negatrve batterycable.
3. Startthe engineand checkfor leaks.
01EOEX017

E-9
 WATERPUMP

WATERPUMP
REMOVAL/ INSTALLATION
Cautlon
l-adfore toosenin' the radlator drain ptug, verity that the radlatordrain hose taces stralght do{vn.
. oJnoi aisasseiule the water purilp.-tta probtemis found, replacethe pumPas a unit'

1. Disconnect the negativebatterycable.

2. Drainthe enginecoolant.
3. Flemove in the ordershownin the figure.
4. lnstallin the reveaseorderof removal.

f_o

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@neeurce

E t
aOREPLAoE

^ _\6

FEPLACE

re-2s 0,9-2.6, t4-re)

1.Timingbelt 4 Waterpumpassembly
B
..... .... Section
Service.........-........ tor cracks,
Inspect damaged mounting
2. Waterintetpipeand gasket surface,bearingcondition,and leakage
3. Waterbypasspipe and O'ring 5. Waterpumpgasket

Steps Aller lnstallaiion

i. Fi|ltn" iio"ioi ritn the spec redamountandtypeot enginecoolant(Referto pageE-5 )
2. Connectthe negativebatterycable.
3. Startthe engineand checkfor leaks.
E-l0
 ELECTRICCOOLINGFAN SYSTEM
ELECTBICCOOLINGFAN SYSTEM
SYSTEMCIRCUIT

COOLING

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TAGNOSTS
CONNECTOF
PBESSUFIE

ADDITIONAL THEFIMOSWITCH
ABOVE91"C (196'F): ON
SWITCH
MAGNETIC
CLUTCH

t-](-%,re SYSTEMINSPECTION
1.Jump acrossthe ian testOFA)terminaland the ground
(GND)terminalof the diagnosis
2. Turntheignition
connector.
switchONandverifythatthefanoperates-
lithe fandoesnotoperate,inspectthecoolingfansystem
components and wiringharness.

0r EoEX.021
3. Removethe radiator cao andplacea thermometer
in the
radiatorfillerneck.
4. Startthe engine.
5. Veritythatthefanoperates whenthecoolanttemperature
is as specified.
Operationtemperalure:above91'C (196'D
lf thefan doesnot operate,checkthe waterthermoswitch.
(Referto pageE-13.)

E-11
E FAN IIOTOR
FAN MOTOR
INSPECTION
1. Checkthatthe batteryis fullycharged.
2. Disconnect the fan motorconnector.
3. Connectthe batteryandan ammeter to thelanmotorcon-
neqor.
4. Verifythatcurrentis as specilied.
Current(A)
It4TX ATX
B3 6.6+1

and/orthetandoesnot
5. ll currentis notwithinspeciiication
turn smoothly, replacethe lan motor'

REPLACEMENT

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Cautlon
; Posiiionthe hose clamp in the orlginal locationon the hose, and squeezethe clamp llghtly
with large plierato ensu.e a good llt.
1. Disconnecl the negativebatterycable.
2. Drainthe enginecoolant.
3. Removein the ordershownin the figure.
4. lnstallin the reverseorderof removal.

7,3-ll x{ (30-110 d*q, 30-95 lDlD)

0,01-o.oit f (0.ra--a.22ciFtg, 015-o 1l lFlb)

0.oa'0,06 Nfl (0JHr,56 crF*!,0.3!H.5o lFlb)

1. Coolingfan connector 3. Coolingfan

2. Fiadiator
cowling 4. Fanmotor

E-12
 WATERTHERMOSWITCH E
WATERTHERMOSWITCH
NE OVAL/ INSTALLATION
1. Disconnect the negativebatterycable
2. Removein the ordershownin the ligure
3. Installin the reverseorderoi removal,referring
to InstallatlonNote.

GFING
FEPLACE

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1.Waterthermoswitch
connector 2. Waterthermoswitch
1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g
. .e.E. .-.l.3. . . . . .
Insialiation Note.......................... pageE-13
INSPECTION
1. Placethe switchand a thermometer
in water.
2. Heatthewatergraduallyandcheckcontinuity
oftheswitch
wilh an ohmmeter.
Coolantlemperalure 'C fD Continuity
[4orethan91 (196)
Lessthan 84 {183)

replacethe waterthermoswitch.
3. lt not as specified,

lnstallationNote
Waterthermoswitch
1. Applya smallamountof enginecoolantto thenewGring.
Caution
. Do not use an impact wrench tor Installatlon.

2. lnstallthe waterthermoswitch.
Tighieninglorque:
5.9-4.8 N.m(60-90 cm-kg, 52-78 innb)
E-13
 FAN RELAY
FAN RELAY
REMOVAL/ INSTALLATION
1. Disconnect the negativebatterycable
2. Remove fan relay.
the
3. Installin the reverseorderof removal.

:-\_

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-=-=l

24
INSPECTION
as shownwithan ohmmeter.
1. Checkcontinuity
Contlnuity
@ @ NO

o @
2. Apply12v betweenlerm,rals6 an{ @;
Checklor contrnuiry betweentermlnals(, ano (9)
the fan relay.
replace
3. lf notas specified,

E-14