Cooling System: Service and Repair

COOLING SYSTEM





COMPONENT

ENGINE COOLANT REFILLING AND BLEEDING

WARNING: Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off immediately.

1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the touch.
2. Remove radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug (A) securely.
5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze.
6. Fill fluid mixture with coolant and water (4:6) slowly through the radiator cap. Push the upper/lower hoses of the radiator so as bleed air easily.

NOTE: Use only genuine antifreeze/coolant. For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum. Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

CAUTION: Do not mix different brands of antifreeze/coolants. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.

7. Start the engine and run coolant circulates.
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan, 3 - 5 times and bleed air sufficiently out of the cooling system.
9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2 - 3 times.
11. Stop the engine and wait coolant gets cool.
12. Repeat 6 to 11 until be coolant level doesn't fall any more, bleed air out 0 the cooling system.

NOTE: Recheck the coolant, level in the reservoir tank for 2 - 3 days after replacing coolant.

CAP TESTING





1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.
2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 19 psi)
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

TESTING
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14.1 psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap,

NOTE: Check for engine oil in the coolant and/or coolant in the engine oil.