Page 257 of 2189

lllustrated Index
@@ system is under high pressure when theengine is hot. To avoid dangsr of rsleasing scaldingengine coolant, removo the cap only when the engine iscoot.
Total Cooling System Capacity flncluding heater andfoservoir (0.4 f (0.42 US qt, 0.35 tmp qt)ll:
*2: 81642 engine*3: D16Y7 engine*4: D16Y8 engine
CAUTION: lf any engine coolant spills on painted por-tions of the body, rinse it off immediately.
NOTE:
. Check all cooling system hoses for damage, leaks ordeterioration and replace if necessary.. Check all hose clamps and retighten if necessary.. Use new O-rings when reassembling.
RADIATOR CAPPressure test, page '10 86x1.0mm9.8 N.m {1.0 kgtm,7.2 tbt.ltl
UPPERRADIATORHOSE
UPPER BRACKETAND CUSHION
COOLANT
RAOIATOREngine coolant refilling and bleeding,page 10 7Leak test, page 10-9Inspect soldered joints andseams for leaks,Blow out dirt Irom betweencore fins with compressed air.lf insects, etc,, are cloggingradiator, wash them off withrow pressure water.
RESERVOIR
5x0.8mmA: ,1.4 N.m {0.45 kgf.m, 3.3 tbtftlg: 5.4 N.m (0.55 kgtm.4.0 tbf.ft)
6x1.0mm7.2 N.m (0.73 kgt.m,5.3 tbtftl
LOWERCUSHION
RADIATOR FANBADIATORFAN
DRAINPLUG
O-RINGReplace.
LOWEBRADIATORHOSE
FAN MOTOR SHROUD
Ar TOYO RADIATOR manufactured radiatorB: NIPPONDENSO manufacfared raoraror
10-2
Refer to section 14when installing.
Mt-|-4.2 f (4.4 US qt,3.7 tmp qt)*j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4.1 f (4.3 US qt, 3.6 lmp q0*3
4.31 (4.5 US qt, 3.8 tmp qt)*a
CVT4.3 f (4.5 US qt,3.8 Imp qt)
*1i D16Y5, D16Y7, D16Y8 engines
iil
Page 258 of 2189
lv
Engine Hose Connections:
D15Y7 engine:
CONNECTINGPIPE
HEATERHOSES
{cont'd)
IAC VALVE
WATEF BYPASS
THERMOSTATHOUSING
VALVE
10-3
Page 259 of 2189
lllustrated Index
(cont'd)
Engine Hose Connections:
D16Y5, D16Y8 engines:
Replace.
IAC VALVE(M/TI
IAC VALVE{A/T)
WATER BYPASSHOSE
THERMOSTATHOUSING
O.RINGReplace.
\
\
\
\h
CONNECTINGPIPE
HEATERVALVE
HEATERHOS€S
10-4
Page 260 of 2189
CONNECTINGPIPE
Engine Hose Conneqtions:
81642 engine:
O-RINGReplace.
b
WATER BYPASSHOSE
HEATERVALVE
HEATERHOSES
THERMOSTATHOUSING
ENGINE OIL COOLER
10-5
Page 261 of 2189
Radiator
Replacement
Drain the engine coolant.
Remove the upper and lower radiator hoses, andATF cooler hoses.
Disconnect the fan motor connector.
Remove the radiator upper bracket, then pull up theraotator,
RADIA
ATF COOLERHOSES (A/T)Refer to sectionwhen installing.
UPPER RAOIATOR HOSE
6x1.0mm7.2 N.m (0.73 kgf.m.5.3 tbf.ft)
1.
2.
3.
5. Remove the fan shroud assemblies and other partsfrom the radiator.
Install the radiator in the reverse order of removal:
NOTE:
. Set the upper and lower cushions securely.. Fill the radiator with engine coolant and bleedthe air.
6x1.0mmCAPY|lT,PS:|" i.i ru- ii b rgr.-,AND CUSHION7.2 tbr.ftl
14
(
I
RESEBVOIR TANK
RADIATOR
LOWER CUSHION
RAOIATOR FAN/SHROUDASSEMBLY
DRAIN PLUGO-RINGReplace.
LOWER RAOIATOR HOSE
ATF COOLERPIPES {A/T)
,iiiiii
10-6
Page 262 of 2189
tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK
Page 263 of 2189

Radiator
Engine Coolant Refilting and Bleeding (cont,dl
8. Mix the recommended antifreeze with an eoualamount of water in a clean container.
NOTE:
o Use only genuine Honda antifreeze/coolant.. For best corrosion protection. the coolant con_centration must be maintained year_round at50% minimum. Coolant concentrations less than50% may not provide sufficient protectionagainst corrosion or freezing.. Coolant concentrations greater than 60010 willimpair cooling efficiency and are not recom_mended.
CAUTION:
. Do not mix difforont brands ofar ilreeze/coolants.. Do not use additional rust inhibiiors or anti_rustproduqt3; they may not be compatible with thecoolant.
Engine Coolent Refi
Capacity Iincluding reservoir{0.4 f 10.42 US qr, 0.35 lmp qt),I;
*1: D16Y5, D16Y/, O16Y8 engines*2: 81642 engine*3; Dl6Y7 engine*4: Dl6Y8 engine
M/r3.8 f {4.0 US qt, 3.3 lmp qt)*1
4.5 / (4.8 US qt. 4.0 tmp qt)*,
Att3.7, (3.9 US qr,3.3 tmp qt).3
3.9 / (4.1 US qt,3.4lmp qt)*.
CW3.9 / (4.1 US qt,3.4 tmp qtl
10-8
\.-I
9. Pour coolant into the radiator up to the base of thefiller neck. and install the radiator cap looselv.
Start the engine and let it run until it warms up (theradiator fan comes on at least twicer.
Turn off the engine. Check the level in the radiator.add coolant if needed.
Put the radiator cap on tightly, then run the engineagain and check for leaks.
10.
11.
Page 264 of 2189
Cap Testing
1. Remove the radiator cap, wet its seal with engine
coolant, then install it on the pressure tester'
RADIATOR PR€SSURE TESTER(CommerciallY available)
RAOIATOR
(for 32 mm neck' low Pro{ile)
Apply a pressure of 93 - 123 kPa (0.95 - 'l 25 kgflcm' '
14 - 18 psi).
Check for a drop in Pressure.
lf the pressure drops, replace the cap
I
t
ADAPTOR
Testing
LWait until the engine is cool, then carefully remove
the radiator cap and fill the radiator with engine
coolant to the top of the tiller neck
Attach the pressure tester to the radiator and apply
a pressure of 93 - '123 kPa (0.95 - 1.25 kgflcm' , 14 -
18 psil.
RADIATOR PRESSURE
TESTER
lCommerciallY available)
ADAPTOR(for 32 mm neck, low Profile)
Inspect for engine coolant leaks and a drop In pres-
sure.
Remove the tester and reinstall the radiator cap
NOTE: Check for engine oil in the coolant and/or
coolant in the engine oil.
10-9