Cooling System: Service and Repair
Changing Engine CoolantWARNING:
To avoid being scalded, never change the coolant when the engine is hot.
DRAINING ENGINE COOLANT
1. Move heater temperature control lever all the way to WARM.
- Make sure blower fan switch is OFF.
2. Open radiator drain plug at the bottom of radiator and remove radiator filler cap.
3. Remove reservoir tank, drain coolant, then clean reservoir tank.
Install it temporarily.
- Be careful not to allow coolant to contact drive belts.
4. Remove cylinder block drain plug and air relief plugs (A) and (B).
5. Close radiator drain plug.
FLUSHING COOLING SYSTEM
6. Fill radiator with water until coolant spills from cylinder block drain plug hole during refill, then reinstall drain plug securely.
7. Fill radiator with water again until coolant spills from the air relief hole during refill, then reinstall air relief plugs (A) and (B).
Then fill radiator and reservoir tank with water.
Air relief plug:
Tighten: 7 - 8 Nm (0.7 - 0.8 kg-m, 61 - 69 in-lb)
8. Reinstall radiator filler cap.
9. Warm up engine until cooling fan operates, then rev engine 2 or 3 times under no-load.
10. Stop engine and wait until it cools down.
11. Repeat steps 2 through 10 until clear water begins to drain from radiator.
12. Drain water.
- Apply sealant to the thread of drain plug on cylinder block.
Tighten 34.3-- 44.1 Nm (3.50- 4.50 kg-m, 25.30-32.53 ft-lb)
13. Reinstall reservoir tank.
REFILLING ENGINE COOLANT
14. Fill radiator with coolant at the speed of less than 2L (2-1/8 US qt, 1-3/4 Imp qt)/min.
- If coolant spills from air relief hole, install the air relief plug and then add coolant again.
- After filling radiator, fill reservoir tank to MAX level line.
15. Install radiator filler cap and air relief plug. Then, start engine and warm up to thermostat opening temperature.
- If coolant level becomes low, refill reservoir tank until coolant level does not change.
16. Run engine at 2,500 rpm for 10 seconds and return to idle speed.
- Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the engine.
17. Stop engine and cool it down.
- Cool down using a fan to reduce the time.
18. Remove radiator filler cap and check coolant level.
- If coolant level becomes low, repeat step 14 through step 17 until coolant level does not change.
19. Refill reservoir tank to MAX level line.
20. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control lever set at several positions between COOL and WARM.
- Sound may be noticeable at heater water cock.
For models without air bleeder on heater inlet hose
21. If the sound is heard, repeat step 15 through step 16 until coolant level does not change.
For models with air bleeder on heater inlet hose
21. If the sound is heard, bleed air from cooling system according to the following steps.
1) Stop engine and cool it down. Then, remove air bleeder cap on heater inlet hose.
2) Attach a suitable transparent hose at air bleeder pipe and put the opposite end of the hose into coolant of reservoir tank.
- Check that coolant level of reservoir tank is not beyond MAX level line.