Engine Coolant Refilling And Bleeding

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 or the paint. If any coolant spills, rinse it off immediately.

1.	Make sure the engine and radiator are cool to the touch.

2.	Remove the radiator cap.

3.	Loosen the drain plug, and drain the coolant.

4.	Tighten the radiator drain plug securely.

5.	Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze.

6.

Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the radiator so as to bleed air easily. • 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 or freezing. • Coolant concentrations greater than 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.

7.	Start the engine and run so coolant circulates. When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.

8.	Repeat 7 until the cooling fan cycles 3 ~ 5 times and bleed air sufficiently out of the cooling system.

9.	Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.

10.	Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.

11.	Stop the engine and wait until coolant gets cool.

12.	Repeat 6 to 11 until the coolant level doesn't fall any more, bleed air out of the cooling system. Bleed air out of the cooling system and refill coolant when coolant completely cools, recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.

Removal

Water Pump

1.	Drain the 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.

2.	Remove the drive belt(A).

3.	Remove the 4 bolts and the pump pulley(A).

4.	Remove the water pump(A) and gasket.

1.	Drain the engine coolant.

2.	Remove the air cleaner assembly.

3.	Disconnect the radiator upper and lower hose(A).

4.	Disconnect the ECT sensor connector.

5.	Disconnect the heater hose, the water vent hose and the water hose from water temperature control assembly.

6.	Remove the wiring protector.

7.	Remove the water temperature control assembly(A).

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.

1.	Drain engine coolant so its level is below thermostat.

2.	Remove the water inlet(A) and the thermostat(B).

1.	Drain the engine coolant.

2.	Remove the air duct(A).

3.	Disconnect the radiator upper and lower hoses(A).

4.	Disconnect transaxle oil cooler hoses.

5.	Disconnect the radiator fan connector.

6.	Remove the radiator bracket.

7.	Remove the radiator.

Inspection

1.	Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.

2.	Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.

3.	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.

1.	Immerse the thermostat in water and gradually heat the water.

2.	Check the valve opening temperature. Valve opening temperature : 82°C (177°F) Full opening temperature : 95°C (205°F) If the valve opening temperature is not as specified, replace the thermostat.

3.	Check the valve lift. Valve lift : Min. 10mm (0.4in.) at 95°C (205°F) If the valve lift is not as specified, replace the thermostat.

1.	Remove the radiator cap, wet its seal with engine coolant, then install it to pressure tester.

2.	Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi)

3.	Check for a drop in pressure.

4.	If the pressure drops, replace the cap.

1.	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.

2.	Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm² 14 ~18psi).

3.	Inspect for engine coolant leaks and a drop in pressure.

4.	Remove the tester and reinstall the radiator cap. Check for engine oil in the coolant and/or coolant in the engine oil.

Installation

Water Pump

1.	Install the water pump(A) and a new gasket(B) with 12 bolts. Tightening torque 21.56 ~ 23.52Nm (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft) 9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) • Clean the contact face before assembly. • Always use a new bolt(C) and gaskets(B).

2.	Install the 4 bolts and the pump pulley(A). Tightening torque 7.84 ~ 9.80Nm (0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

3.	Install the drive belt(A).

4.	Fill with engine coolant.

5.	Start engine and check for leaks.

6.	Recheck engine coolant level.

Clean the contact face before assembly.

1.	Install the water temperature control assembly(B) and a new gasket(A). Tightening torque 18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft) Use new O-rings(C) when reassembling.

2.	Connect water hoses to the water temperature control assembly.

3.	Install the wiring protector.

4.	Connect the ECT sensor connector.

5.	Connect the radiator upper and lower hose(A).

6.	Install the air cleaner assembly.

7.	Fill with engine coolant.

8.	Start engine and check for leaks.

9.	Recheck engine coolant level.

1.	Place the thermostat in thermostat housing. (1) Install the thermostat with the jiggle valve upward. (2) Install a new thermostat(B).

2.	Install the water inlet(A). Tightening torque 16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft)

3.	Fill with engine coolant.

4.	Start engine and check for leaks.

1.	Install the radiator.

2.	Install the radiator bracket.

3.	Reconnect the radiator fan connector.

4.	Connect the transaxle oil cooler hoses.

5.	Connect the radiator upper and lower hoses(A).

6.	Install the air duct(A).

7.	Fill with engine coolant.

8.	Start engine and check for leaks.

9.	Recheck engine coolant level.