CO-38
< ON-VEHICLE MAINTENANCE >[MR18DE]
RADIATOR
RADIATOR
Checking Radiator CapINFOID:0000000001337842
Check valve seat of radiator cap.
- Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.
Pull negative-pressure valve to open it, and make sure that it is
completely closed when released.
- Make sure that there is no dirt or damage on the valve seat of radi-
ator cap negative-pressure valve.
- Make sure that the valve operates properly in the opening and
closing conditions.
Check radiator cap relief pressure using suitable tool.
- When connecting the radiator cap to the tester, apply water or
coolant to the cap seal surface.
- Replace the radiator cap if there is an abnormality in the negative-
pressure valve, or if the open-valve pressure is outside of the stan-
dard values.
Replace radiator cap if there it does not comply to specifications to the above three checks.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking RadiatorINFOID:0000000001337843
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud
and horns. Then tape harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2, 71 psi) and keep distance more than 30 cm
(11.8 in).
PBIC2816E
SMA967B
Standard: 78 – 98 kPa (0.78 - 0.98 bar, 0.8 – 1.0 kg/cm2, 11
– 14 psi)
Limit: 59 kPa (0.59 bar, 0.6 kg/cm
2, 9 psi)
WBIA0570E
THERMOSTAT
CO-45
< ON-VEHICLE REPAIR >[MR18DE]
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THERMOSTAT
ComponentINFOID:0000000001337850
Removal and InstallationINFOID:0000000001337851
REMOVAL
1. Drain engine coolant. Refer to CO-35, "Changing Engine Coolant".
2. Remove water inlet.
3. Remove thermostat.
4. Remove water pump. Refer to CO-44, "
Removal and Installation".
5. Remove thermostat housing.
INSPECTION AFTER REMOVAL
Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) filled with water. Heat while
stirring.
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full open valve lift amount.
After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
1. Thermostat housing 2. Water hose 3. Radiator hose (lower)
4. Water inlet 5. Thermostat 6. Rubber ring
7. Gasket A. To oil cooler B. To radiator
Engine front
PBIC4485E
PBIC3314J
WATER OUTLET AND WATER CONTROL VALVE
CO-47
< ON-VEHICLE REPAIR >[MR18DE]
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WATER OUTLET AND WATER CONTROL VALVE
ComponentINFOID:0000000001337852
Removal and InstallationINFOID:0000000001337853
REMOVAL
1. Drain engine coolant. Refer to CO-35, "Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
2. Remove air duct. Refer to EM-154, "
Component".
3. Remove radiator hose (upper). Refer to CO-40, "
Component".
4. Remove heater hoses and water hoses.
5. Remove water outlet.
6. Remove water control valve.
7. Remove engine coolant temperature sensor, if necessary.
CAUTION:
Handle carefully to avoid any shock to engine coolant temperature sensor.
Replace the gasket with a new one.
INSPECTION AFTER REMOVAL
1. Engine coolant temperature sensor 2. Rubber ring 3. Water control valve
4. Gasket 5. Water hose 6. Gasket
7. Water hose 8. Water outlet 9. Heater hose
10. Heater hose 11. Radiator hose (upper) 12. Water hose
A. To heater B. To electronic throttle control actuator C. To oil cooler
D. To radiator Front
WBIA0856E
CO-52
< FUNCTION DIAGNOSIS >[K9K]
DESCRIPTION
FUNCTION DIAGNOSIS
DESCRIPTION
Engine Cooling SystemINFOID:0000000001381580
1. Engine 2. Radiator 3. Heater core
4. Reservoir tank 5. Water pump 6. Thermostat
7. Air relief plug 8. Oil cooler 9. EGR cooler
MBIB9046E
CO-56
< PRECAUTION >[K9K]
PRECAUTIONS
CAUTION:
Be careful not to damage the mating surfaces.
Tap Tool to insert it (1), and then slide it by tapping on the side (2)
as shown.
In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
CAUTION:
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, using scraper.
Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
3. Attach liquid gasket tube to Tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-27, "
Recommended Chemical Prod-
ucts and Sealants".
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.
If there is a groove for the liquid gasket application, apply liquid gasket to the groove.
As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.
Within five minutes of liquid gasket application, install the mat-
ing component.
If liquid gasket protrudes, wipe it off immediately.
Do not retighten nuts or bolts after the installation.
After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them. Tool number : KV10111100 (J-37228)
WBIA0566E
Tool number : WS39930000 ( — )
PBIC0003E
WBIA0567E
SEM159F
CO-60
< ON-VEHICLE MAINTENANCE >[K9K]
RADIATOR
RADIATOR
Checking Radiator CapINFOID:0000000001538671
Check valve seat of radiator cap.
- Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.
Pull negative-pressure valve to open it, and make sure that it is
completely closed when released.
- Make sure that there is no dirt or damage on the valve seat of radi-
ator cap negative-pressure valve.
- Make sure that the valve operates properly in the opening and
closing conditions.
Check radiator cap relief pressure using suitable tool.
- When connecting the radiator cap to the tester, apply water or
coolant to the cap seal surface.
- Replace the radiator cap if there is an abnormality in the negative-
pressure valve, or if the open-valve pressure is outside of the stan-
dard values.
Replace radiator cap if there it does not comply to specifications to the above three checks.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking RadiatorINFOID:0000000001538672
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud
and horns. Then tape harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2, 71 psi) and keep distance more than 30 cm
(11.8 in).
PBIC2816E
SMA967B
Standard: 78 – 98 kPa (0.78 - 0.98 bar, 0.8 – 1.0 kg/cm2, 11
– 14 psi)
Limit: 59 kPa (0.59 bar, 0.6 kg/cm
2, 9 psi)
WBIA0570E
DEF-36
< ON-VEHICLE REPAIR >
FILAMENT
ON-VEHICLE REPAIR
FILAMENT
Inspection and RepairINFOID:0000000001697576
INSPECTION
1. When measuring voltage, wrap tin foil around the top of the neg-
ative probe. Then press the foil against the wire with your finger.
2. Attach probe circuit tester (in Volt range) to middle portion of
each filament.
3. If a filament is burned out, circuit tester registers 0 or battery
voltage.
4. To locate burned out point, move probe to left and right along fil-
ament. Test needle will swing abruptly when probe passes the
point.
REPAIR
REPAIR EQUIPMENT
Conductive silver composition (Dupont No. 4817 or equivalent)
SEL122R
SEL263
SEL265
EC-5
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P Component Function Check ..................................
316
Diagnosis Procedure .............................................316
Component Inspection (Fuel Pump) .....................318
IGNITION SIGNAL ...........................................319
Description ............................................................319
Component Function Check ..................................319
Diagnosis Procedure .............................................319
Component Inspection (Ignition Coil with Power
Transistor) .............................................................
322
Component Inspection (Condenser) .....................322
MALFUNCTION INDICATOR ...........................324
Description ............................................................324
Component Function Check ..................................324
Diagnosis Procedure .............................................324
POSITIVE CRANKCASE VENTILATION ........325
Description ............................................................325
Component Inspection ..........................................325
REFRIGERANT PRESSURE SENSOR ...........326
Description ............................................................326
Component Function Check ..................................326
Diagnosis Procedure .............................................326
ECU DIAGNOSIS .......................................328
ECM ..................................................................328
Reference Value ...................................................328
Wiring Diagram - ENGINE CONTROL SYSTEM - ..339
Fail Safe ...............................................................358
DTC Inspection Priority Chart .............................360
DTC Index ............................................................361
How to Set SRT Code ........................................363
Test Value and Test Limit ..................................365
SYMPTOM DIAGNOSIS ............................366
ENGINE CONTROL SYSTEM SYMPTOMS ....366
Symptom Table .....................................................366
NORMAL OPERATING CONDITION ...............370
Description ............................................................370
PRECAUTION ............................................371
PRECAUTIONS ................................................371
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
371
Precaution for Procedure without Cowl Top Cover ..371
Precautions For Xenon Headlamp Service ...........371
On Board Diagnostic (OBD) System of Engine
and A/T ..................................................................
372
General Precautions .............................................372
PREPARATION .........................................375
PREPARATION ................................................375
Special Service Tools ............................................375
Commercial Service Tools ....................................375
ON-VEHICLE MAINTENANCE ..................377
FUEL PRESSURE ...........................................377
Inspection ..............................................................377
EVAPORATIVE EMISSION SYSTEM .............379
Inspection ..............................................................379
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
380
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
380
Idle Speed .............................................................380
Ignition Timing .......................................................380
Calculated Load Value ..........................................380
Mass Air Flow Sensor ............................................380
HR16DE (WITHOUT EURO-OBD)
BASIC INSPECTION .................................
381
DIAGNOSIS AND REPAIR WORKFLOW ......381
Work Flow ..............................................................381
Diagnostic Work Sheet ..........................................383
INSPECTION AND ADJUSTMENT ................385
BASIC INSPECTION ...............................................385
BASIC INSPECTION : Special Repair Require-
ment .......................................................................
385
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ......................................................
388
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ...............................
388
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement ....
388
IDLE SPEED ............................................................388
IDLE SPEED : Description ....................................389
IDLE SPEED : Special Repair Requirement .........389
IGNITION TIMING ....................................................389
IGNITION TIMING : Description ............................389
IGNITION TIMING : Special Repair Requirement ..389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING ...............................................................
389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING : Description .......................................
389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING : Special Repair Requirement ............
389
THROTTLE VALVE CLOSED POSITION LEARN-
ING ...........................................................................
390
THROTTLE VALVE CLOSED POSITION
LEARNING : Description .......................................
390
THROTTLE VALVE CLOSED POSITION
LEARNING : Special Repair Requirement ............
390
IDLE AIR VOLUME LEARNING ..............................390
IDLE AIR VOLUME LEARNING : Description .......390