CO-38
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ENGINE COOLANT
4. Install the Tool by installing the radiator cap adapter onto the
radiator neck opening. Then attach the gauge body assembly
with the refill tube and the venturi assembly to the radiator cap
adapter.
5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed
position.
• Use recommended coolant or equivalent.
Refer to MA-11, "FOR USA AND CANADA : Fluids and Lubri-
cants".
CAUTION:
Do not use any cooling system additives such as radiator
sealer. Additives may clog th e cooling system and cause
damage to the engine, transm ission and/or cooling system.
6. Install an air hose to the venturi assembly, the air pressure must be within specification.
CAUTION:
The compressed air supply must be equipped with an air dryer.
7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open the ball valve on the refill hose slightly. Coolant will be vi sible rising in the refill hose. Once the refill hose is
full of coolant, close the ball valve. This will purge any air trapped in the refill hose.
8. Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude
locations, use the vacuum specifications based on the altitude
above sea level.
9. When the vacuum gauge has reached the specifi ed amount, disconnect the air hose and wait 20 seconds
to see if the system loses any vacuum. If the vacuum level drops, perform any necessary repairs to the
system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for any leaks.
10. Place the coolant container (with the refill hose insert ed) at the same level as the top of the radiator. Then
open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling
system is full when the vacuum gauge reads zero.
CAUTION:
Do not allow the coolant container to get too low when filling, to avoid air from being drawn into
the cooling system.
11. Remove the Tool from the radiator neck opening.
12. Fill the cooling system reservoir tank to the specif ied level and install the radiator cap. Run the engine to
warm up the cooling system and t op up the system as necessary.
13. Install the engine under cover. Refer to EXT-17, "Removal and Installation"
.
FLUSHING COOLING SYSTEM
Tool number : KV991J0070 (J-45695)
Engine coolant capacity
(with reservoir tank) : Refer to
CO-53, "Capacity"
.
Compressed air
supply pressure : 549 - 824 kPa (5.6 - 8.4 kg/cm
2,
80 - 119 psi)
LLIA0058E
Altitude above sea level Vacuum gauge reading
0 - 100 m (328 ft) : 28 inches of vacuum
300 m (984 ft) : 27 inches of vacuum
500 m (1,641 ft) : 26 inches of vacuum
1,000 m (3,281 ft) : 24 - 25 inches of vacuum
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ENGINE COOLANTCO-39
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1. Fill the radiator from the filler neck above the r
adiator upper hose and reservoir tank with clean water and
reinstall radiator filler cap.
2. Run the engine until it reaches normal operating temperature.
3. Rev the engine two or three times under no-load.
4. Stop the engine and wait until it cools down.
5. Drain the water from the system. Refer to CO-36, "Changing Engine Coolant"
.
6. Repeat steps 1 through 5 until clear water begins to drain from the radiator.
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CO-40
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RADIATOR
REMOVAL AND INSTALLATION
RADIATOR
Exploded ViewINFOID:0000000009460415
WARNING:
Do not remove the radiator cap when the engine is hot. Serious burns could occur from high-pressure
engine coolant escaping from the radiator. Wrap a th ick cloth around the cap. Slowly push down and
turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing it down
and turning it all the way.
NOTE:
When removing components such as hoses, tubes/lines, etc. , cap or plug openings to prevent fluid from spill-
ing.
1. Radiator 2. CVT oil cooler hose 3. Radiator hose (upper)
4. Radiator hose (lower) 5. Radiator core support 6. Reservoir tank
7. Reservoir tank cap 8. Reservoir tank hose 9. Radiator filler cap
10. Filler neck 11. Filler neck hose A. To CVT
B. To water outlet C. To water inlet
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RADIATORCO-41
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Removal and InstallationINFOID:0000000009460416
REMOVAL
1. Remove radiator cap and drain coolant from radiator. Refer to
CO-12, "Changing Engine Coolant".
CAUTION:
• Perform this step when the engine is cold.
• Do not spill coolant on the drive belt.
2. Remove front air duct. Refer to EM-29, "Removal and Installation"
.
3. Disconnect coolant reservoir hose from the radiator.
4. Remove fender protector side cover (LH/RH). Refer to EXT-26, "FENDER PROTECTOR : Exploded
View".
5. Disconnect radiator hose (upper) and radiat or hose (lower) from the radiator.
CAUTION:
Do not allow the coolant to contact the drive belt.
NOTE:
The radiator hose clamps on the radiator hose (upper ) and on the radiator hose (lower), are not serviced
separately. Radiator hose clamps are part of the radiator hose assembly and serviced as one unit with the
radiator hose.
6. Disconnect the CVT oil cooler hoses.
7. Remove the front bumper fascia. Refer to EXT-17, "Removal and Installation"
.
8. Remove A/C condenser. Refer to HA-30, "COMPRESSOR : Removal and Installation"
.
CAUTION:
Be careful not to damage condenser core.
9. Remove the radiator mounts (upper).
10. Remove radiator. CAUTION:
Do not damage or scratch the radiator core when removing.
INSTALLATION
Installation is in the reverse order of removal.
• After installation, refill coolant and check for leaks. Refer to CO-12, "Changing Engine Coolant"
and CO-11,
"System Inspection".
CAUTION:
Do not spill coolant in engi ne compartment. Use a shop cloth to absorb coolant.
InspectionINFOID:0000000009460417
INSPECTION AFTER INSTALLATION
• Check that the reservoir tank cap is tightened.
• Check for leakage of engine coolant using Tool (B) and suitable tool (A). Refer to CO-35, "System Inspection"
.
WARNING:
Do not remove the radiator cap wh en the engine is hot. Seri-
ous burns could occur from high pressure coolant escaping
from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
• Start and warm up the engine. Visually check that there is no leakage of engine coolant and CVT fluid (CVT
models). Tool number : EG17650301 (J-33984-A)
Testing pressure : Refer to CO-53, "Radiator"
.
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CO-42
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COOLING FAN
COOLING FAN
Exploded ViewINFOID:0000000009460418
WARNING:
Do not remove the radiator cap when the engine is hot. Serious burns could occur from high-pressure
engine coolant escaping from the radiator. Wrap a th ick cloth around the cap. Slowly push down and
turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing it down
and turning it all the way.
NOTE:
• When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling.
• Replace the radiator shroud and cooling fan assembly as a unit. Do not replace cooling fan motors or cool-
ing fan blades separately.
Removal and InstallationINFOID:0000000009460419
REMOVAL
1. Partially drain engine coolant from the radiator. Refer to CO-36, "Changing Engine Coolant".
CAUTION:
• Perform when engine is cold.
• Do not spill coolant on the drive belt.
2. Remove engine room cover. Refer to EM-28, "Removal and Installation"
.
1. Radiator core support 2. Fan shroud and motor assembly 3. Grommet
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3. Remove the core support cover clips (A), then remove the core
support cover (1).
4. Remove front air duct. Refer to EM-144, "Removal and Installation"
.
5. Remove air cleaner and air duct assembly. Refer to EM-29, "Removal and Installation"
.
6. Remove battery tray and battery tray bracket. Refer to PG-74, "Removal and Installation (Battery Tray)"
.
7. Disconnect radiator hose (upper) from radiator.
8. Disconnect the harness connectors from the fan motor.
9. Remove fan shroud and motor assembly.
INSTALLATION
Installation is in the reverse order of removal.
• After installation refill engine coolant and check for leaks. Refer to CO-36, "Changing Engine Coolant"
and
CO-35, "System Inspection"
.
CAUTION:
Do not spill coolant in engi ne compartment. Use a shop cloth to absorb coolant.
• Cooling fans are controlled by ECM. Refer to EC-598, "On Board Diagnosis Function"
.
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CO-44
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WATER PUMP
WATER PUMP
Exploded ViewINFOID:0000000009460420
Removal and InstallationINFOID:0000000009460421
WARNING:
Do not remove the radiator cap when the engine is hot. Serious burns could occur from high-pressure
engine coolant escaping from the radiator. Wrap a th ick cloth around the cap. Slowly push down and
turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing it down
and turning it all the way.
CAUTION:
• When removing water pump assembly, be car eful not to get coolant on drive belt.
• Water pump cannot be disassembled and must be replaced as a unit.
• After installing the water pump, connect hose and clamp securely, then check for leaks. Repair as
necessary.
NOTE:
When removing components such as hoses, tubes/lines, etc. , cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Disconnect the negative battery terminal. Refer to PG-73, "Removal and Installation (Battery)".
2. Remove the core support cover clips (A), then remove the core support cover (1).
3. Remove front air duct. Refer to EM-84, "Removal and Installation"
.
1. Timing chain tensioner (primary) 2. Valve timing control cover gasket
(bank 1)3. Valve timing cont
rol cover (bank 1)
4. Water pump cover 5. O-ring 6. O-ring
7. Water pump A. Engine oil B. Identify with white mark
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4. Remove cowl top extension. Refer to
EXT-24, "Removal and Installation".
5. Remove the front road wheel and tire (RH). Refer to WT-55, "Adjustment"
.
6. Remove the fender protector (RH). Refer to EXT-26, "FENDER PROTECTOR : Removal and Installation"
.
7. Drain coolant from the radiator. Refer to CO-36, "Changing Engine Coolant"
.
CAUTION:
Perform when the engine is cold.
8. Disconnect coolant reservoir hose and remove coolant reservoir tank. Refer to CO-40, "Exploded View"
.
9. Drain the power steering fluid reservoir. Refer to ST-30, "Draining and Refilling"
.
10. Remove the power steering oil pump. Refer to ST-38, "Removal and Installation"
.
11. Support engine and remove the RH engine insulator and bracket. Refer to EM-220, "Exploded View"
.
12. Set No. 1 cylinder at TDC on its compression stroke. • Align pointer with TDC mark on crankshaft pulley.
13. Remove drive belt. Refer to EM-134, "Removal and Installation"
.
14. Remove the drive belt auto-tensioner assembly. Refer to EM-135, "Removal and Installation of Drive Belt
Auto-tensioner".
15. Remove water drain plug (A) and copper sealing washer (B) to drain coolant from engine.
CAUTION:
Do not reuse copper sealing washers.
16. Disconnect RH valve timing control connectors and remo ve valve timing control cover (bank 1). Refer to
EM-182, "Exploded View"
.
17. Remove water pump cover. Refer to CO-44, "Exploded View"
.
18. Remove the timing chain tensioner (primary) as follows:
a. Pull the lever (C) down to release the plunger stopper tab (B).
b. Insert the stopper pin A into the tensioner body hole to hold the lever (C) and keep the plunger stopper tab (B) released.
NOTE:
An allen wrench [(1.2 mm (0.047 in)] is used for a stopper pin A
as an example.
c. Compress the plunger (D) into the tensioner body (1) by press- ing the slack guide (2).
d. Keep the slack guide (2) pressed and lock the plunger (D) in by pushing the stopper pin A through the lever (C) and into the
chain tensioner body hole.
e. Remove timing chain tensioner bolts and then remove the timing chain tensioner. CAUTION:
Be careful not to drop timing chain te nsioner bolts inside timing chain case.
19. Remove the three water pump bolts (A). Make a gap between water pump sprocket (1) and timing chain, by carefully turning
crankshaft pulley (2) counterclockwise until timing chain loosens
on water pump sprocket (1).
: Front
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