ENGINE LUBRICATION &

COOLING SYSTEMS GI

SECTION LC MA

EM

EC

CONTENTS FE

ENGINE LUBRICATION SYSTEM..................................2 CHECKING COOLING SYSTEM FOR LEAKS ............13

AT
Precautions ..................................................................2 Water Pump ...............................................................13
LIQUID GASKET APPLICATION PROCEDURE ............2 REMOVAL AND INSTALLATION ...............................13 TF
Preparation ..................................................................2 REMOVAL ...............................................................14
SPECIAL SERVICE TOOLS ........................................2 INSPECTION ...........................................................15
COMMERCIAL SERVICE TOOL ..................................3 INSTALLATION........................................................15 PD
Lubrication Circuit ........................................................3 Thermostat.................................................................17
Oil Pressure Check......................................................5 REMOVAL AND INSTALLATION ...............................17
Oil Pump ......................................................................6 INSPECTION ...........................................................18 AX
REMOVAL AND INSTALLATION .................................6 Water Control Valve...................................................19
DISASSEMBLY AND ASSEMBLY................................6 REMOVAL AND INSTALLATION ...............................19
OIL PUMP INSPECTION ............................................7 INSPECTION ...........................................................20 SU
REGULATOR VALVE INSPECTION ............................7 Radiator .....................................................................21
OIL FILTER ...............................................................8 REMOVAL AND INSTALLATION ...............................21
Oil Cooler.....................................................................8 Cooling Fan (Crankshaft driven) ...............................22 BR
REMOVAL AND INSTALLATION .................................8 REMOVAL AND INSTALLATION ...............................22
INSPECTION .............................................................9 INSPECTION ...........................................................22
Service Data and Specifications (SDS).......................9 Refilling Engine Coolant ............................................22 ST
OIL PRESSURE ........................................................9 Cooling Fan (Motor driven)........................................23
REGULATOR VALVE .................................................9 REMOVAL AND INSTALLATION ...............................23
DISASSEMBLY AND ASSEMBLY..............................23
RS
OIL PUMP .................................................................9
ENGINE COOLING SYSTEM........................................10 Radiator (Aluminum type)..........................................24
Precautions ................................................................10 PREPARATION .......................................................24 BT
LIQUID GASKET APPLICATION PROCEDURE ..........10 DISASSEMBLY ........................................................24
Preparation ................................................................10 ASSEMBLY .............................................................25
SPECIAL SERVICE TOOLS ......................................10 INSPECTION ...........................................................26 HA
Cooling Circuit ...........................................................11 Overheating Cause Analysis .....................................27
System Check............................................................12 Service Data and Specifications (SDS).....................28
CHECKING COOLING SYSTEM HOSES ...................12 THERMOSTAT ........................................................28 SC
CHECKING RADIATOR ............................................12 WATER CONTROL VALVE .......................................28
CHECKING RADIATOR CAP ....................................12 RADIATOR ..............................................................28
EL

IDX
 ENGINE LUBRICATION SYSTEM
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE NBLC0001
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine liquid gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

Preparation
SPECIAL SERVICE TOOLS NBLC0002

Tool number
Description
Tool name

ST25051001
Oil pressure gauge

NT050

ST25052000 Adapting oil pressure gauge to upper oil pan

Hose

NT559

WS39930000 Pressing the tube of liquid gasket

Tube pressure

NT052

LC-2
 ENGINE LUBRICATION SYSTEM
Preparation (Cont’d)
COMMERCIAL SERVICE TOOL NBLC0040

Tool name Description GI

Deep socket Removing and installing oil pressure switch
Deep socket 26 mm, 3/8 drive
MA

EM

NT818

EC

FE

AT

TF
Lubrication Circuit NBLC0003
PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
SLC350BF

IDX

LC-3
 ENGINE LUBRICATION SYSTEM
Lubrication Circuit (Cont’d)

SLC493B

LC-4
ENGINE LUBRICATION SYSTEM
Oil Pressure Check

Oil Pressure Check NBLC0004

WARNING:
I Be careful not to burn yourself, as the engine and oil may GI
be hot.
I Oil pressure check should be done in “Parking position”.
MA
1. Check oil level.
2. Disconnect oil pressure switch harness connector.
3. Remove oil pressure switch using a deep socket. (Commercial EM
service tool)
4. Install pressure gauge.
5. Start engine and warm it up to normal operating temperature.
6. Check oil pressure with engine running under no-load.
Engine speed Approximate discharge pressure EC
rpm kPa (bar, kg/cm2, psi)

Idle speed More than 98 (0.98, 1.0, 14) FE

2,000 294 (2.94, 3.0, 43)

If difference is extreme, check oil passage and oil pump AT

for oil leaks.
7. After the inspections, install the oil pressure switch as follows.
SLC497BA a. Remove the old sealant adhering to switch and engine. TF
b. Apply Genuine liquid gasket or equivalent to the thread and
tighten.
PD
13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)

AX

SU

BR
SLC926-A

ST

RS

BT

HA

SC

EL

IDX

LC-5
 ENGINE LUBRICATION SYSTEM
Oil Pump

Oil Pump
REMOVAL AND INSTALLATION =NBLC0005
1. Remove timing chain. Refer to EM-22, “Removal”.
2. Remove oil pump assembly.
I Inspect the oil pump after removing it.
3. Reinstall any parts removed in reverse order of removal.
DISASSEMBLY AND ASSEMBLY NBLC0006

SLC494BA

I When installing oil pump, apply engine oil to rotors.

LC-6
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
OIL PUMP INSPECTION NBLC0007
I Install oil pump with the groove of the inner rotor facing
the oil pump cover. GI
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in) MA
Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer gear tip clearance Below 0.18 (0.0071)

EM
2
SLC324B Body to inner rotor axial clearance 3 0.030 - 0.070 (0.0012 - 0.0028)

Body to outer rotor axial clearance 4 0.050 - 0.110 (0.0020 - 0.0043)

Inner rotor to brazed portion of hous- 0.045 - 0.091 (0.0018 - 0.0036) EC

ing clearance 5

I If the tip clearance (2) exceeds the limit, replace rotor set. FE
I If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace oil pump body assembly.
AT

SLC932A
TF

PD

AX

SU

BR
SLC933A

ST

RS

BT

HA
SLC934AB

REGULATOR VALVE INSPECTION NBLC0008

SC
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring. EL
3. Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
IDX
If damaged, replace regulator valve set or oil pump body.

SLC251B

LC-7
 ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
4. Check regulator valve to oil pump body clearance.
Clearance:
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump body.

SLC935AA

OIL FILTER NBLC0009

The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
I Use Tool specified in MA-20 for changing oil filter.

ALC094

Oil Cooler
REMOVAL AND INSTALLATION NBLC0036

SLC332BC

1. Disconnect water hoses from oil cooler, pinching water hose to

prevent coolant spill.
I Do not spill coolant on the drive belt.
2. Remove oil cooler.
LC-8
 ENGINE LUBRICATION SYSTEM
Oil Cooler (Cont’d)
I Inspect the oil cooler after removing it.

GI

MA

EM

3. Installation is in reverse order of removal.

I When installing the oil cooler, align the oil cooler stopper
with the stopper of the oil cooler bracket.
EC
INSPECTION
Oil Cooler
NBLC0037
FE
NBLC0037S01
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant inlet. AT
If necessary, replace oil cooler assembly.
Oil Pressure Relief Valve
SLC333B
NBLC0037S02 TF
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with a suitable tool. Install a new valve in place by PD
tapping it.

AX

SU

BR

Service Data and Specifications (SDS) ST

OIL PRESSURE NBLC0010

Engine speed Approximate discharge pressure

rpm kPa (bar, kg/cm2, psi)
RS
Idle speed More than 98 (0.98, 1.0, 14)
2,000 294 (2.94, 3.0, 43) BT
REGULATOR VALVE NBLC0011
Unit: mm (in) HA
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)

OIL PUMP
SC
NBLC0012
Unit: mm (in)

Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079) EL

Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

Body to inner rotor axial clearance 0.030 - 0.070 (0.0012 - 0.0028) IDX
Body to outer rotor axial clearance 0.050 - 0.110 (0.0020 - 0.0043)

Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)

LC-9
 ENGINE COOLING SYSTEM
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE NBLC0013
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine liquid gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

Preparation
SPECIAL SERVICE TOOLS NBLC0014

Tool number
Description
Tool name

WS39930000 Pressing the tube of liquid gasket

Tube pressure

NT052

EG17650301 Adapting radiator cap tester to radiator filler neck

Radiator cap tester a: 28 (1.10) dia.
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

NT564

KV99103510 Installing radiator upper and lower tanks

Radiator plate pliers A

NT224

KV99103520 Removing radiator upper and lower tanks

Radiator plate pliers B

NT225

LC-10
ENGINE COOLING SYSTEM
Cooling Circuit

Cooling Circuit NBLC0015

GI

MA

EM

EC

FE

AT

TF

PD

SLC321BC
AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

SLC513BB

LC-11
 ENGINE COOLING SYSTEM
System Check

System Check NBLC0016

WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES NBLC0016S01
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR NBLC0016S02
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
I Be careful not to bend or damage the radiator fins.
I When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically downward.
I Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 ,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.

CHECKING RADIATOR CAP NBLC0016S03

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
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/cm2, 9 psi)

SLC755AA

Pull the negative pressure valve to open it.

Check that it closes completely when released.

SMA967B

LC-12
 ENGINE COOLING SYSTEM
System Check (Cont’d)
CHECKING COOLING SYSTEM FOR LEAKS NBLC0016S04
To check for leakage, apply pressure to the cooling system with a
tester. GI
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
MA
CAUTION:
Higher than the specified pressure may cause radiator
damage. EM

SLC756AA

Water Pump
REMOVAL AND INSTALLATION NBLC0017
EC
CAUTION:
I When removing water pump assembly, be careful not to
get coolant on drive belt. FE
I Water pump cannot be disassembled and should be
replaced as a unit.
I After installing water pump, connect hose and clamp
AT
securely, then check for leaks using radiator cap tester.
TF

PD

AX

SU

BR

ST

RS

BT

HA

SC
SLC509BA

EL

IDX

LC-13
 ENGINE COOLING SYSTEM
Water Pump (Cont’d)
REMOVAL NBLC0018
1. Remove under cover.
2. Remove suspension member stay.
3. Drain coolant from radiator.
4. Remove radiator shrouds.
5. Remove drive belts.
6. Remove cooling fan.
7. Remove water drain plug on water pump side of cylinder block.
8. Remove chain tensioner cover and water pump cover.

SLC499BA

9. Pushing timing chain tensioner sleeve, apply a stopper pin so

it does not return. Then remove the chain tensioner assembly.

SLC328B

10. Remove the 3 water pump fixing bolts. Secure a gap between
water pump gear and timing chain, by turning crankshaft pul-
ley 20° backwards.

SLC941A

11. Put M8 bolts [pitch: 1.25 mm (0.0492 in), length: approx. 50

mm (1.97 in)] to two water pump fixing bolt holes.

JLC357B

LC-14
 ENGINE COOLING SYSTEM
Water Pump (Cont’d)
12. Tighten M8 bolts by turning half turn alternately until they reach
timing chain rear case.
I In order to prevent damages to water pump or timing chain rear GI
case, do not tighten one bolt continuously. Always turn each
bolt half turn each time.
13. Lift up water pump and remove it. MA
I When lifting up water pump, do not allow water pump gear to
hit timing chain.
EM

EC

FE

AT

TF

PD

AX

SU

BR
SLC116B

INSPECTION
1. Check for badly rusted or corroded body assembly.
NBLC0019 ST
2. Check for rough operation due to excessive end play.
RS

BT

HA
SLC943A

INSTALLATION NBLC0020
SC
1. Apply engine oil and coolant to O-rings as shown in the figure.
I Locate the O-ring with white paint mark to engine front side.
EL

IDX

PBIC0855E

LC-15
 ENGINE COOLING SYSTEM
Water Pump (Cont’d)
2. Install water pump.
I Do not allow cylinder block to nip O-rings when installing
water pump.

SLC031B

3. Return the crankshaft pulley to its original position by turning

it 20° forward.

SLC156B

4. Install timing chain tensioner, then remove the stopper pin.

I When installing the timing chain tensioner, engine oil
should be applied to the oil hole and tensioner.

SLC961A

5. Install chain tensioner cover and water pump cover.

a. Before installing, remove all traces of liquid gasket from mat-
ing surface of water pump cover and chain tensioner cover
using a scraper.
Also remove traces of liquid gasket from mating surface of
front cover.

SLC944A

LC-16
 ENGINE COOLING SYSTEM
Water Pump (Cont’d)
b. Apply a continuous bead of liquid gasket to mating surface of
chain tensioner cover and water pump cover.
Use Genuine Liquid Gasket or equivalent. GI

MA

EM

EC

FE

AT

SLC500BA
TF
6. Reinstall any parts removed in reverse order of removal.
I After starting engine, let idle for three minutes, then rev PD
engine up to 3,000 rpm under no load to purge air from the
high-pressure chamber of the chain tensioners. The
engine may produce a rattling noise. This indicates that AX
air still remains in the chamber and is not a matter of
concern.
SU

BR

Thermostat ST
REMOVAL AND INSTALLATION NBLC0021

RS

BT

HA

SC

EL

IDX

SLC510BB

LC-17
 ENGINE COOLING SYSTEM
Thermostat (Cont’d)
1. Remove under cover.
2. Remove suspension member stay.
3. Drain coolant from radiator.
4. Remove drive belts.
5. Remove water drain plug on water pump side of cylinder block.
6. Disconnect lower radiator hose.
7. Remove water inlet and thermostat assembly.
I Do not disassemble water inlet and thermostat assembly.
Replace them as a unit, if necessary.
SLC962AB

8. Install water inlet and thermostat assembly with jiggle valve

facing upward.
I After installation, run engine for a few minutes, and check
for leaks.
I Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
9. Reinstall any removed parts in reverse order of removal.

SLC948A

INSPECTION NBLC0022
1. Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard

Valve opening temperature 76.5°C (170°F)

Valve lift More than 8.6 mm/90°C

(0.339 in/194°F)

SLC949A 3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.

LC-18
 ENGINE COOLING SYSTEM
Water Control Valve

Water Control Valve

REMOVAL AND INSTALLATION NBLC0032
GI

MA

EM

EC

FE

AT

SLC490BA
TF
1. Water outlet housing 4. Water hose 7. Engine coolant temperature sen-
sor
2. Water control valve 5. Cylinder block water outlet PD
3. Water outlet 6. Thermal transmitter

1. Release fuel pressure.

AX
Refer to EC-39, “Fuel Pressure Release”.
2. Remove under cover. SU
3. Remove suspension member stay.
4. Drain coolant from radiator.
5. Remove engine cover. BR
6. Remove air duct with air cleaner assembly.
7. Disconnect wires, hoses, harness and so on. ST
8. Remove upper intake manifold corrector.
9. Remove intake manifold corrector support bolts.
10. Remove lower intake manifold corrector. RS
11. Disconnect injector harness connectors.
12. Remove injector tube. BT
13. Remove intake manifold.
14. Remove water outlet housing and water control valve.
HA

15. Install water control valve and water outlet housing. SC

a. Install gum ring to thermostat.
b. Point the arrow on the upper surface of the valve to the front
of the engine, and also be sure to install the protrusions and EL
the valve stopper so that they are aligned in a straight line.
16. Reinstall any removed parts in reverse order of removal.
IDX
I When installing intake manifold, injector tube and intake
manifold collectors, refer to EM-11, “TIGHTENING PROCE-
DURES”.
I After installation, run engine for a few minutes, and check
SLC334B for leaks.

LC-19
 ENGINE COOLING SYSTEM
Water Control Valve (Cont’d)
I Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.

INSPECTION NBLC0033
1. Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard

Valve opening temperature 95°C (203°F)

Valve lift More than 8.0 mm/108°C

(0.315 in/226°F)

SLC252B 3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.

LC-20
 ENGINE COOLING SYSTEM
Radiator

Radiator
REMOVAL AND INSTALLATION
1. Remove under cover.
=NBLC0023
GI
2. Remove suspension member stay.
3. Drain coolant from radiator. MA
4. Disconnect radiator upper and lower hoses.
5. Remove upper and lower radiator shroud.
6. Remove A/T oil cooler hoses.
EM
7. Disconnect reservoir tank hose.
8. Remove radiator mounting bracket.
9. Remove radiator.
10. After repairing or replacing radiator, install any part removed in reverse order of removal.
EC
When filling radiator with coolant, refer to MA-15, “Changing Engine Coolant”.

FE

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA
SLC501B

SC

EL

IDX

LC-21
 ENGINE COOLING SYSTEM
Cooling Fan (Crankshaft driven)

Cooling Fan (Crankshaft driven)

REMOVAL AND INSTALLATION =NBLC0038
I Do not release the drive belt tension by removing the fan/water
pump pulley.
I Fan coupling cannot be disassembled and should be replaced
as a unit. If front mark F is present, install fan so that side
marked F faces the front.
I Install the drive belt only after the fan and fan coupling to water
pump flange bolts/nuts have been properly torqued.
I Proper alignment of these components is essential. Improper
SLC066B
alignment will cause them to wobble and may eventually cause
the fan to separate from the water pump causing extensive
damage.

INSPECTION NBLC0039
Check fan coupling for rough operation, wobbling, oil leakage or
bent bimetal.

SLC067B

After assembly, verify the fan does not wobble or flap while the
engine is running.
WARNING:
I When the engine is running, keep hands and clothing
away from moving parts such as drive belts and fan.

SLC151B

Refilling Engine Coolant NBLC0034

For details on refilling engine coolant, refer to MA-16, “REFILLING
ENGINE COOLANT”.

LC-22
ENGINE COOLING SYSTEM
Cooling Fan (Motor driven)

Cooling Fan (Motor driven)

REMOVAL AND INSTALLATION =NBLC0041
GI

MA

EM

EC

FE

AT

SLC503B
TF
Removal NBLC0041S01
1. Remove front grille. Refer to BT-5, “Body Front End”. PD
2. Remove engine undercover.
3. Remove harness connector from fan motor.
4. Remove fan grille.
AX
Installation
Install in the reverse order of removal.
NBLC0041S02
SU
Cooling fan is controlled by ECM. For details. Refer to EC-236, “DTC
P1217 Engine Over Temperature”.
BR

DISASSEMBLY AND ASSEMBLY NBLC0042 ST

Disassembly NBLC0042S01
1. Remove fan from fan motor.
2. Remove fan motor from fan grille. RS
Assembly NBLC0042S02
I Install in the reverse order of removal. BT

HA

SC

EL

IDX

LC-23
 ENGINE COOLING SYSTEM
Radiator (Aluminum type)

Radiator (Aluminum type)

PREPARATION NBLC0025

SLC511B

1. Attach the spacer to the tip of the radiator plate pliers A. Spacer
specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) wide
x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.

SLC655C

DISASSEMBLY NBLC0026
1. Remove upper and lower tanks with Tool.

SLC903

I Grip the crimped edge and bend it upwards so that Tool slips
off.
Do not bend excessively.

SLC893

LC-24
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
I In areas where Tool cannot be used, use a screwdriver to bend
the edge up.
Be careful not to damage tank. GI
2. Remove sealing rubbers.
MA

EM

SLC930

3. Make sure the edge stands straight up.

4. Remove oil cooler from tank.
EC

FE

AT

SLC931
TF
ASSEMBLY NBLC0027
1. Install oil cooler. PD
Pay attention to direction of conical washer.
AX

SU

BR
SLC894

2. Clean contact portion of tank.

ST

RS

BT

HA
SLC932

3. Install sealing rubber. SC

Push it in with fingers.
Be careful not to twist sealing rubber.
EL

IDX

SLC917A

LC-25
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
4. Caulk tank in specified sequence with Tool.

SLC904

SLC896

I Use pliers in the locations where Tool cannot be used.

SLC897

5. Make sure that the rim is completely crimped down.

Standard height “H”:
8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
Refer to Inspection.

SLC554A

INSPECTION NBLC0028
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler to seal its inlet and outlet.

SLC933

LC-26
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
2. Check for leakage by soaking radiator in water container.

GI

MA

EM

SLC934

Overheating Cause Analysis NBLC0029

Symptom Check items EC

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed —

FE
Dust contamination or
Poor heat transfer Damaged fins paper clogging — AT
Physical damage

Clogged radiator cooling Excess foreign material TF

tube (rust, dirt, sand, etc.)

Cooling fan does not oper- PD

ate

Reduced air flow High resistance to fan rota- Fan assembly —

tion AX
Damaged fan blades

Damaged radiator shroud — — — SU

Improper coolant mixture
— — —
Cooling sys- ratio BR
tem parts
malfunction Poor coolant quality — Coolant density —

Loose clamp ST
Cooling hose
Cracked hose

Water pump Poor sealing RS

Loose
Radiator cap
Poor sealing BT
Coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting HA
Radiator
Cracked radiator tank

Cracked radiator core SC

Reservoir tank Cracked reservoir tank

Cylinder head deterioration EL

Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
IDX

LC-27
 ENGINE COOLING SYSTEM
Overheating Cause Analysis (Cont’d)

Symptom Check items

High engine rpm under no

load

Driving in low gear for

Abusive driving
extended time

Driving at extremely high

speed
— Overload on engine
Powertrain system mal-
function

Installed improper size

Except cool- wheels and tires —
ing system
parts mal- Dragging brakes
function
Improper ignition timing

Blocked bumper —

Installed car brassiere

Blocked radiator grille Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator —

Blocked condenser
Blocked airflow
Installed large fog lamp

Service Data and Specifications (SDS)

THERMOSTAT NBLC0030

Valve opening temperature 76.5°C (170°F)

Valve lift More than 8.6 mm/90°C (0.339 in/194°F)

WATER CONTROL VALVE NBLC0035

Valve opening temperature 95°C (203°F)

Valve lift More than 8.0 mm/108°C (0.315 in/226°F)

RADIATOR NBLC0031
Unit: kPa (bar, kg/cm2, psi)

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Cap relief pressure
Limit 59 (0.59, 0.6, 9)

Leakage test pressure 157 (1.57, 1.6, 23)

LC-28