Page 297 of 4770
THERMOSTAT REMOVAL
HINT: Removal of the thermostat would have an ad±
verse effect, causing a lowering of cooling efficiency.
Do not remove the thermostat, even if the engine
tends to overheat.
1. DRAIN ENGINE COOLANT (See page EG1±241)
2. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228±06500
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts and water inlet from the water
pump.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.
THERMOSTAT
COMPONENTS FOR REMOVAL AND
INSTALLATION
± 5S±FE ENGINECOOLING SYSTEMEG1±247
Page 298 of 4770

THERMOSTAT INSTALLATION
(See Components for Removal and Installation)
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the upper
side of the stud bolt, and insert the thermostat in the
water pump.
HINT: The jiggle valve may be set within 5of either
side of the prescribed position.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N±m (90 kgf±cm, 78in.±Ibf)
(c) Check the valve lift.
Valve rift:
8 mm (0.31 in.) or more at 95C (203F)
If the valve lift is not as specified, replace the thermo±
stat.
(d) Check that the valve spring is tight when the thermo±
stat is fully closed.
If not closed, replace the thermostat. (a) Immerse the thermostat in water and gradually heat
the water.
(b) Check the valve opening temperature.
Valve opening temperature:
80 ± 84C (176 ± 183F)
If the valve opening temperature is not as specified,
replace the thermostat.
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve
opening temperature.
± 5S±FE ENGINECOOLING SYSTEMEG1±248
Page 299 of 4770
7. CHECK ENGINE OIL LEVEL
The oil level should be between the ªLº and ªFº marks
on the dipstick.
If low, check for leakage and add oil up to ªFº mark. (c) Tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting. Then using
SST, give it an additional 3/4 turn to seat the oil filter.
SST 09228±06500
4. FILL WITH ENGINE OIL
5. FILL WITH ENGINE COOLANT (SEE PAGE EG1±241)
6. START ENGINE AND CHECK FOR LEAKS 3. INSTALL OIL FILTER
(a) Clean the oil filter contact surface on the filter
mounting.
(b) Lubricate the filter rubber gasket with engine oil.
± 5S±FE ENGINECOOLING SYSTEMEG1±249
Page 300 of 4770

1. INSPECT RADIATOR CAP
NOTICE: When performing steps (a) and (b) below, keep
the radiator pump tester at an angle of over 30 above
the horizontal.
(a) Using a radiator cap tester, slowly pump the tester
and check that air is coming from the relief valve.
Pump speed:
1 push/ 3 seconds or more
NOTICE: Push the pump at a constant speed.
If air is not coming from the relief valve, replace the
radiator cap.
(b) Pump the tester several times and measure the relief
valve opening pressure.
Pump speed:
1 at time
1 push/1 second or less
2nd time or more
Any speed
Standard opening pressure:
74±103 kPa
(0.75±1.05 kgf/cm, 10.7 ± 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm, 8.5 psi)
If the opening pressure is less than minimum, replace
the radiator cap.
RADIATOR
RADIATOR CLEANING
Using water or a steam cleaner, remove any mud or
dirt from the radiator core.
NOTICE: If using a high pressure type cleaner, be care±
full not to deform the fins of the radiator core. If the
cleaner nozzle pressure is 2,942 ± 3,432 kPa (30 ± 35
kgf/cm, 427 ± 498 psi), keep a distance of at least 40
cm (15.75 in.) between the radiator core and cleaner
nozzle.
RADIATOR INSPECTION
± 5S±FE ENGINECOOLING SYSTEMEG1±250
Page 301 of 4770
2. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm, 17.1 psi), and check
that the pressure does not drop.
If the pressure drops, check the hoses, radiator or
water pump for leaks. If no external leaks are found,
check the heater core, cylinder block and head.
RADIATOR REMOVAL
1. DISCONNECT NEGATIVE (±) TERMINAL CABLE
FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ªLOCKº
position and the negative (±) terminal cable is discon±
nected from the battery.
COMPONENTS FOR REMOVAL AND
INSTALLATION
± 5S±FE ENGINECOOLING SYSTEMEG1±251
Page 302 of 4770
2. DRAIN ENGINE COOLANT (See page EG1±241)
3. w/ CRUISE CONTROL SYSTEM:
REMOVE CRUISE CONTROL ACTUATOR COVER
4. DISCONNECT ENGINE COOLANT TEMPERATURE
SWITCH CONNECTOR FROM FAN SHROUD
5. DISCONNECT ELECTRIC COOLING FAN
CONNECTORS
9. REMOVE RADIATOR AND ELECTRIC COOLING
FANS
(a) Remove the 2 bolts and 2 upper supports.
(b) Lift out the radiator.
(c) Remove the 2 lower radiator supports. 6. DISCONNECT RADIATOR HOSES
(a) Disconnect the upper hose from the radiator side.
(b) Disconnect the lower from the water inlet pipe.
7. DISCONNECT ENGINE COOLANT RESERVOIR
HOSE
10. REMOVE RADIATOR LOWER HOSE
11. A/T:
REMOVE A/T OIL COOLER HOSES 8. A/T:
DISCONNECT OIL COOLER HOSES
± 5S±FE ENGINECOOLING SYSTEMEG1±252
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14. REMOVE ENGINE COOLANT TEMPERATURE
SWITCH
(a) Remove the engine coolant temperature switch.
(b) Remove the 0±ring. 13. REMOVE ELECTRIC COOLING FANS FROM
RADIATOR
Remove the 8 bolts and cooling fans.12. REMOVE ENGINE COOLANT TEMPERATURE
SWITCH WIRE
± 5S±FE ENGINECOOLING SYSTEMEG1±253
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RADIATOR DISASSEMBLY
1. ASSEMBLE SST
SST 09230±01010
(a) Install the claw to the overhaul handle, inserting it in
the hole in part ªAº as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so
that dimension ªBº shown in the diagram is 0.2±0.5
mm (0.008±0.020 in.).
NOTICE: If this adjustment is not performed, the claw
may be damaged.
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
± 5S±FE ENGINECOOLING SYSTEMEG1±254