CO-1
ENGINE
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SECTION CO
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CONTENTS
ENGINE COOLING SYSTEM
HR16DE
FUNCTION DIAGNOSIS ...............................
4
DESCRIPTION ....................................................4
Engine Cooling System .............................................4
Engine Cooling System Schematic ...........................5
SYMPTOM DIAGNOSIS ...............................6
OVERHEATING CAUSE ANALYSIS ..................6
Troubleshooting Chart ...............................................6
PRECAUTION ...............................................8
PRECAUTIONS ...................................................8
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
8
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .....................................
8
Precaution for Liquid Gasket .....................................8
PREPARATION ...........................................10
PREPARATION ..................................................10
Special Service Tool ...............................................10
Commercial Service Tool ........................................10
ON-VEHICLE MAINTENANCE ....................11
ENGINE COOLANT ...........................................11
Inspection ................................................................11
Changing Engine Coolant .......................................11
RADIATOR .........................................................14
Checking Radiator Cap ...........................................14
Checking Radiator ...................................................14
ON-VEHICLE REPAIR .................................16
RADIATOR .........................................................16
Component ..............................................................16
Removal and Installation .........................................16
COOLING FAN ..................................................18
Component (Models with A/C) .................................18
Component (Models without A/C) ............................18
Removal and Installation .........................................19
WATER PUMP ..................................................20
Exploded View .........................................................20
Removal and Installation .........................................20
Inspection ................................................................21
THERMOSTAT ..................................................22
Exploded View .........................................................22
Removal and Installation .........................................22
Inspection ................................................................23
WATER OUTLET ..............................................24
Exploded View .........................................................24
Removal and Installation .........................................24
Inspection ................................................................25
DISASSEMBLY AND ASSEMBLY ..............26
COOLING FAN ..................................................26
DISASSEMBLY AND ASSEMBLY ..........................26
SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................
27
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
27
Periodical Maintenance Specification ......................27
Radiator ...................................................................27
Thermostat ..............................................................27
MR18DE
FUNCTION DIAGNOSIS ..............................
28
COOLING SYSTEM ..........................................28
Cooling Circuit .........................................................28
CO-2
SYMPTOM DIAGNOSIS .............................30
OVERHEATING CAUSE ANALYSIS ................30
Troubleshooting Chart ............................................30
PRECAUTION .............................................32
PRECAUTIONS .................................................32
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
32
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................
32
Precaution for Liquid Gasket ..................................32
PREPARATION ...........................................34
PREPARATION .................................................34
Special Service Tool ...............................................34
Commercial Service Tool .......................................34
ON-VEHICLE MAINTENANCE ...................35
ENGINE COOLANT ...........................................35
Inspection ...............................................................35
Changing Engine Coolant .......................................35
RADIATOR ........................................................38
Checking Radiator Cap ..........................................38
Checking Radiator ..................................................38
ON-VEHICLE REPAIR ................................40
RADIATOR ........................................................40
Component .............................................................40
Removal and Installation ........................................40
COOLING FAN ..................................................42
Component (Models with A/C) ................................42
Component (Models without A/C) ...........................42
Removal and Installation ........................................43
WATER PUMP ...................................................44
Component .............................................................44
Removal and Installation ........................................44
THERMOSTAT ..................................................45
Component .............................................................45
Removal and Installation ........................................45
WATER OUTLET AND WATER CONTROL
VALVE ...............................................................
47
Component .............................................................47
Removal and Installation ........................................47
DISASSEMBLY AND ASSEMBLY .............50
COOLING FAN ..................................................50
DISASSEMBLY AND ASSEMBLY .........................50
SERVICE DATA AND SPECIFICATIONS
(SDS) ...........................................................
51
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
51
Standard and Limit ..................................................51
K9K
FUNCTION DIAGNOSIS ............................
52
DESCRIPTION ...................................................52
Engine Cooling System .........................................52
SYMPTOM DIAGNOSIS ............................53
OVERHEATING CAUSE ANALYSIS ................53
Troubleshooting Chart ............................................53
PRECAUTION ............................................55
PRECAUTIONS .................................................55
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
55
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................
55
Precaution for Liquid Gasket ...................................55
PREPARATION ..........................................57
PREPARATION .................................................57
Special Service Tools .............................................57
Commercial Service Tools ......................................57
ON-VEHICLE MAINTENANCE ..................58
ENGINE COOLANT ...........................................58
Inspection ................................................................58
Draining ...................................................................58
Refilling ...................................................................58
Flushing ..................................................................59
RADIATOR ........................................................60
Checking Radiator Cap ...........................................60
Checking Radiator ..................................................60
ON-VEHICLE REPAIR ...............................62
RADIATOR ........................................................62
Exploded View ........................................................62
Removal and Installation .........................................62
Inspection ................................................................63
COOLING FAN ..................................................64
Exploded View ........................................................64
Removal and Installation .........................................64
Disassembly and Assembly ....................................65
Inspection ................................................................65
WATER PUMP ...................................................66
Exploded View ........................................................66
Removal and Installation .........................................66
Inspection ................................................................66
CO-6
< SYMPTOM DIAGNOSIS >[HR16DE]
OVERHEATING CAUSE ANALYSIS
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting ChartINFOID:0000000001381552
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or pa-
per clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio———
Poor engine coolant quality — Engine coolant viscosity —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Reservoir tank capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into cool-
ing systemCylinder head deterioration
Cylinder head gasket deteri-
oration
OVERHEATING CAUSE ANALYSIS
CO-7
< SYMPTOM DIAGNOSIS >[HR16DE]
C
D
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F
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CO
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P O
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for ex-
tended time
Driving at extremely high
speed
Power train system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or paper
clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items
CO-30
< SYMPTOM DIAGNOSIS >[MR18DE]
OVERHEATING CAUSE ANALYSIS
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting ChartINFOID:0000000001337836
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed Thermostat
Damaged finsDust contamination or pa-
per clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly— High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — —
Improper engine coolant
mixture ratio—
—
Engine coolant viscosity—
Poor engine coolant quality — —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into cool-
ing systemCylinder head deterioration
Cylinder head gasket deteri-
oration
OVERHEATING CAUSE ANALYSIS
CO-31
< SYMPTOM DIAGNOSIS >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
CO
N
P O
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for ex-
tended time
Driving at extremely high
speed
Power train system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
Installed front bumper fas-
cia cover
— Blocked radiator grille
Mud contamination or paper
clogging
Blocked radiator
—
Blocked air flow Blocked condenser
Installed large fog lamp Symptom Check items
OVERHEATING CAUSE ANALYSIS
CO-53
< SYMPTOM DIAGNOSIS >[K9K]
C
D
E
F
G
H
I
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K
L
MA
CO
N
P O
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting ChartINFOID:0000000001381581
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn timing belt
— Thermostat stuck closed —
Damaged finsDust contamination or pa-
per clogging
Mechanical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper coolant mixture
ratio———
Poor coolant quality — — —
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Reservoir tank capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into cool-
ing systemCylinder head deterioration
Cylinder head gasket deteri-
oration
CO-54
< SYMPTOM DIAGNOSIS >[K9K]
OVERHEATING CAUSE ANALYSIS
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for ex-
tended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or paper
clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp Symptom Check items