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CO-1
ENGINE
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SECTION CO
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CONTENTS
ENGINE COOLING SYSTEM
FUNCTION DIAGNOSIS .. .............................2
DESCRIPTION ............................................... .....2
Engine Cooling System ..................................... ......2
Engine Cooling System Schematic .........................2
SYMPTOM DIAGNOSIS ...............................3
OVERHEATING CAUSE ANALYSIS ............. .....3
Troubleshooting Chart ........................................ ......3
PRECAUTION ...............................................5
PRECAUTIONS .............................................. .....5
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
5
Liquid Gasket ...........................................................5
PREPARATION ............................................7
PREPARATION .............................................. .....7
Special Service Tool ........................................... ......7
Commercial Service Tools .......................................7
ON-VEHICLE MAINTENANCE .....................8
ENGINE COOLANT ....................................... .....8
Inspection ............................................................ ......8
Draining .....................................................................8
Refilling .....................................................................9
Flushing ...................................................................10
RADIATOR .........................................................12
RADIATOR CAP .................................................... ....12
RADIATOR CAP : Inspection ..................................12
RADIATOR ............................................................ ....12
RADIATOR : Inspection ..........................................12
ON-VEHICLE REPAIR .................................13
RADIATOR ....... ................................ .................13
Exploded View ..................................................... ....13
Removal and Installation .........................................13
Inspection ................................................................15
COOLING FAN ..................................................16
Exploded View .........................................................16
Removal and Installation .........................................16
Disassembly and Assembly .....................................17
Inspection ................................................................17
WATER PUMP ..................................................18
Exploded View .........................................................18
Removal and Installation .........................................18
Inspection ................................................................21
WATER INLET AND THERMOSTAT ASSEM-
BLY ....................................................................
23
Exploded View .........................................................23
Removal and Installation .........................................23
Inspection ................................................................24
WATER OUTLET AND WATER PIPING ..........25
Exploded View .........................................................25
Removal and Installation .........................................25
Inspection ................................................................26
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .............................................
27
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
27
Periodical Maintenance Specification .................. ....27
Radiator ...................................................................27
Thermostat ..............................................................27
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OVERHEATING CAUSE ANALYSIS
CO-3
< SYMPTOM DIAGNOSIS >
C
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SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting ChartINFOID:0000000003793161
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 density —
Insufficient engine coolantEngine coolant leakageCooling 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 leakage into
cooling systemCylinder head deterioration
Cylinder head gasket deteri-
oration
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CO-4
< SYMPTOM DIAGNOSIS >
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
Blocked air flow
Installed large fog lamp Symptom Check items