Repair Procedures
Removal
Water Pump
1. Drain the engine coolant.
WARNING:
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
2. Remove the drive belt(A).
3. Remove the 4 bolts and the pump pulley(A).
4. Remove the water pump(A) and gasket.
Water Temperature Control Assembly
1. Drain the engine coolant.
2. Remove the air cleaner assembly.
3. Disconnect the radiator upper and lower hose(A).
4. Disconnect the ECT sensor connector.
5. Disconnect the heater hose, the water vent hose and the water hose from water temperature control assembly.
6. Remove the wiring protector.
7. Remove the water temperature control assembly(A).
Thermostat
NOTE:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.
1. Drain engine coolant so its level is below thermostat.
2. Remove the water inlet(A) and the thermostat(B).
Radiator
1. Drain the engine coolant.
2. Remove the air duct(A).
3. Disconnect the radiator upper and lower hoses(A).
4. Disconnect transaxle oil cooler hoses.
5. Disconnect the radiator fan connector.
6. Remove the radiator bracket.
7. Remove the radiator.
Inspection
Water Pump
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.
NOTE:
A small amount of "weeping" from the bleed hole is normal.
Thermostat
1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature.
Valve opening temperature :82°C (177°F)
Full opening temperature :95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift :Min. 10mm (0.4in.) at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
Installation
Water Pump
1. Install the water pump(A) and a new gasket(B) with 12 bolts.
Tightening torque
21.56 - 23.52Nm (2.2 - 2.4kgf.m, 15.91 - 17.36lb-ft)
9.80 - 11.76Nm (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
NOTE:
- Clean the contact face before assembly.
- Always use a new bolt(C) and gaskets(B).
2. Install the 4 bolts and the pump pulley(A).
Tightening torque
7.84 - 9.80Nm (0.8 - 1.0kgf.m, 5.78 - 7.23lb-ft)
3. Install the drive belt(A).
4. Fill with engine coolant.
5. Start engine and check for leaks.
6. Recheck engine coolant level.
Water Temperature Control Assembly
NOTE:
Clean the contact face before assembly.
1. Install the water temperature control assembly(B) and a new gasket(A).
Tightening torque
18.62 - 23.52Nm (1.9 - 2.4kgf.m, 13.74 - 17.36lb-ft)
NOTE:
Use new O-rings(C) when reassembling.
2. Connect water hoses to the water temperature control assembly.
3. Install the wiring protector.
4. Connect the ECT sensor connector.
5. Connect the radiator upper and lower hose(A).
6. Install the air cleaner assembly.
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Recheck engine coolant level.
Thermostat
1. Place the thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new thermostat(B).
2. Install the water inlet(A).
Tightening torque
16.66 - 19.60Nm (1.7 - 2.0kgf.m, 12.30 - 14.47lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.
Radiator
1. Install the radiator.
2. Install the radiator bracket.
3. Reconnect the radiator fan connector.
4. Connect the transaxle oil cooler hoses.
5. Connect the radiator upper and lower hoses(A).
6. Install the air duct(A).
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Recheck engine coolant level.