Initial Inspection and Diagnostic Overview

System Check

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
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
- Be careful not to bend or damage the radiator fins.
- When radiator is cleaned without removal, remove all surrounding 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 vertically 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 radiator.
4. Blow air into the back side of radiator core vertically downward.
- Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.8 inch).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CHECKING RADIATOR CAP





To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi)





Pull the negative pressure valve to open it.
Check that it closes completely when released.

CHECKING COOLING SYSTEM FOR LEAKS





To check for leakage, apply pressure to the cooling system with a tester.
Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

CAUTION: Higher than the specified pressure may cause radiator damage.