COOLING

SYSTEM
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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE COOLANT TEMPERATURE SENDER, SENSOR.... 16
WATER HOSE AND PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
25-2 GENERAL

GENERAL
SPECIFICATIONS

Cooling method Water-cooled, pressurized,

Forced circulation with electrical fan
Cooling system
Quantity 5.5 lit (5.8 [Link]., 5.2 [Link].)
Radiator
Type Pressurized corrugated fin type
Performance 38000 kcal/h
Radiator cap
Main valve opening pressure 81.4-108 kPa (11.8-15.6 psi, 0.83-1.1 kg/cm2)
Vacuum valve opening pressure -6.86 kPa (-1.00 psi, -0.07 kg/cm2) or less
Coolant pump Centrifugal type impeller
Thermostat
Type Wax pellet type with jiggle valve
Valve opening temperature 88º (190°F)
Full-opening temperature 100°C (212°F)
Valve lift, fully open 8.5 mm (0.33 in) or more at 100°C (212°F)
Identification mark 88 (Stamped on flange)
Drive belt
Type V-ribbed belt
Engine coolant temperature sender
Type Thermistor type
Resistance 90.5-117.5 Q at 70°C (158°F)
Thermo switch (on radiator) 21.3-26.3 Sz at 115°C (239°F)
Operating temperature
OFF+ON 85±3ºC (185±5.4ºF)
ON-KIFF 78°C (172°F) or more
Engine coolant temperature sensor
Type Heat-sensitive thermistor type
Switching temperature Switches “ON” at 50°C (122°F) or more
Automatic transaxle oil cooler
Performance 1,200 kcal/h

SERVICE STANDARD
Standard value
Coolant concentration 50%

TIGHTENING TORQUE [Link]

Nm [Link]
Alternator support bolt and nut 20-25 200-250 14-18
Alternator brace bolt 15-22 150-220 11-16
Alternator brace mounting bolt 20-28 200-280 14-20
Coolant pump pulley 8-10 80-100 6-7
Engine coolant temperature sender 8-10 80-100 6-7
Engine coolant temperature sensor 15-20 150-200 9-14
Coolant outlet fitting bolt 15-20 150-200 11-14
Thermostat housing bolt 15-20 150-200 11-14
 GENERAL 25-3

TROUBLESHOOTING

Symptom Probable cause Remedy

Low coolant level Leakage of coolant
Heater or radiator hose Repair or replace parts
Faulty radiator cap Tighten clamps or replace
Thermostat housing Replace gasket or housing
Radiator Repair or replace
Coolant pump Replace parts
Clogged radiator Foreign material in coolant Replace coolant
Abnormally high coolant Faulty thermostat Replace parts
temperature Faulty radiator cap Replace parts
Restriction to flow in cooling system Clear restriction or replace parts
Loosen or missing drive belt Adjust or replace
Faulty coolant pump Replace
Faulty temperature gauge or wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo-switch in radiator Replace
Insufficient coolant Refill coolant

Abnormally low coolant Faulty thermostat Replace

temperature Faulty temperature gauge or wiring Repair or replace

Leakage from oil cooling Loosen connections Retighten

system Cracked or damaged: Replace
Hoses Repair or replace
Pipes Repair or replace
Oil cooler
Inoperative electrical Damaged:
cooling fan Thermo sensor Replace or repair
Electrical motor
Radiator fan relay
Wiring
25-4 GENERAL

COOLANT LEAK CHECK

1. Wait until radiator is cool (less than 38ºC, 100°F). Loosen
radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply
139.3 kPa (19.9 psi, 1.4 kg/cm2) pressure. Maintain pressure
for two minutes, while checking for leakage from the radiator,
hoses or connections.
CAUTION
Radiator coolant may be extremely hot. Do not open the
system while hot, or scalding water could spray out
causing personal injury. Allow vehicle to cool before
servicing this system.
Be sure to completely clean away any moisture from the
places checked.
When the tester is removed, be careful not to spill any
coolant from it.
Be careful, when installing and removing the tester and
when testing, not to deform the filler neck of the radiator.

4. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE TEST

1. Use an adapter to attach the cap to the tester.
2. Increase the pressure unit the gauge stops moving.
Main valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
2
78-108 kPa (11.3-15.6 psi, 0.8-1. kg/cm )

3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or
above the limit.
NOTE
Be sure that the cap is clean before testing, since rust or
other foreign material on the cap seal will cause an
incorrect indication.

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature, and calculate the concentra-
tion from the relation between the specific gravity and tempera-
ture, using the following table for reference.
 GENERAL 25-5

Relation Between Coolant Concentration and Specific Gravity

The following table is applicable only to the specified HIGH QUALITY ETHYLENE GLYCOL (ANTIFREEZE) COOLANT

Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at engine Coolant
temperature of 20°C (68ºF).
CAUTION
If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease,
affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the
specified range.
Do not mix different brands of antifreeze.

RECOMMENDED COOLANT
Antifreeze Mixture ratio of antifreeze in coolant
ETHYLENE GLYCOL 50%
BASE FOR ALUMINUM
25-6 GENERAL

DRIVE BELT TENSION DEFLECTION

CHECK AND ADJUSTMENT
Length of Drive Belt
There are two methods to check drive belt adjustment:
1. Apply 100 N (22 Ibs) force by either pulling or pushing the
belt at position “A” measure the deflection and compare with
specifications.
2. Use a belt tension gauge at position “A”.
 GENERAL 25-7

USING A BELT TENSION GAUGE

Measuring Method
1. Press down on the tension gauge handle and insert the belt
between the spindle and hook of the gauge.
2. Release the handle and read the measurement on the gauge.

NIPPONDENSO

NOTE
1. Belt which has been in operation for 5 minutes or more,
must be adjusted to the used belt specifications.
2. Ensure that the belt is installed correctly, as shown in the
illustration.
3. A loose belt will produce a high-pitched squealing noise.
4. A belt that is too tight will damage the alternator and water
pump bearing.
Incorrect Correct Incorrect
25-8 COOLING SYSTEM

DRIVE BELT AND PULLEY

Removal
1. Loosen the water pump pulley bolts.
2. Loosen the alternator support nut
3. Loosen the alternator lock bolt, and remove the belt.
4. Remove the water pump pulley bolts and remove the water
pump pulley.
Tightening torque
Alternator support nut A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-25 Nm (200-250 [Link], 14-18 [Link])
Alternator lock bolt B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-22 Nm (150-220 [Link], 10.8-15.9 [Link])

Inspection
Check the following items and replace if defective.
1. Check the belt surface for damage, peeling or cracks.
2. Check the belt surface for oil or grease.
3. Check the belt for worn or hardened areas.
4. Check the surface of the pulley for cracks or damage.

Installation
1. Install the water pump pulley to the water pump pulley bracket
and tighten the bolts firmly.
2. After installing the belt, adjust the belt tension. See “DRIVE
BELT TENSION DEFLECTION-CHECK AND ADJUSTMENT”.
 RADIATOR

RADIATOR
COMPONENTS

Reservior tank
25-10 RADIATOR

REMOVAL
1. Disconnect the-radiator fan motor connector.
2. Set the temperature of the heater control to the hot position.
3. Loosen the radiator drain plug to drain coolant.
4. Disconnect the upper and lower hose, and the overflow tube.
5. For vehicles with an automatic transaxles, disconnect the oil
cooler hoses from the automatic transaxle.

CAUTION
Plug the ends of the oil cooler hoses and the
automatic transaxle fittings to prevent transaxle
fluid from spilling out and foreign material from
entering.

6. Remove the radiator mounting bolts.

7. Remove the radiator together with the fan motor.
8. Remove the fan motor from the radiator.

INSPECTION
1. Check the radiator for bent, broken or plugged fins.
2. Check the radiator for corrosion, damage, rust or scale.
3. Check the radiator hoses for cracks, damage or deterioration.
4. Check the reservoir tank for damage.
5. Check the radiator cap spring for damage. Pressure test the cap
using a cooling system checker.
6. Check the radiator cap seal for cracks or damage.

7. Check the radiator fan coolant temperature switch for continuity

with the switch immersed in hot water.
Continuity at 85±3ºC (185±5.4ºF)
No continuity at 78ºC (172ºF)

NOTE
Immerse the switch in hot water up to mounting
threads to check for continuity.

Radiator Fan Motor

1. Check that the radiator fan rotates when battery voltage is

applied to the terminals (as shown in the figure).
2. Check that abnormal noises are not produced while the motor
is turning.
 RADIATOR 25-11

INSTALLATION
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the thermostat opens, and then stop the
engine.
3. Remove the radiator cap, and add coolant up to the filler neck
of the radiator, and then fill the reservoir tank to the
upper level.
4. Check that there is no leakage from the radiator, hoses or
connections.
25-12 RADIATOR CAP

RADIATOR CAP

COMPONENTS

WHEN THE PRESSURE RISES TO THE SPECIFIED WHEN THE PRESSURE IS REDUCED TO THE SPECIFIED
2
LEVEL [81.4-108 kPa (0.83-1.1 kg/cm, 11.8-15.6psi)] LEVEL [-6.86 kPa (-0.07 kg/cm -1.00 psi)]

INSPECTION
1. Check the radiator cap for damage, cracks and deterioration.

2. Attach a radiator cap tester to the radiator cap.

3. Pump the tester until the pointer stabilizes.
4. If the pointer stays constant for 10 sec. at a point exceeding the
service limit, the radiator cap is good.
 COOLANT PUMP 25-13

COOLANT PUMP
COMPONENTS

TORQUE : Nm ([Link], [Link])

REMOVAL
1. Drain the coolant and disconnect the radiator outlet hose from
the coolant pump.
2. Remove the drive belt and coolant pump pulley.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the coolant pump mounting bolts and remove the
alternator brace.
5. Remove the coolant pump assembly from the cylinder block.

INSPECTION
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 water pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole “A”,
the seal is defective. Replace the coolant pump assembly.
25-14 WATER PUMP

INSTALLATION
1. Clean the gasket surfaces of the coolant pump body and cylinder
block.
2. Install the new O-ring onto the groove on the front and of the
coolant pipe, then wet the O-ring with coolant. Do not apply oil
or grease.

3. Install a new coolant pump gasket to the coolant pump and

tighten the bolts to specified torque.
Tightening toque
Coolant pump to cylinder block . . . . . . . . . . . . . . . . . . .
12-15 Nm (120-150 [Link], 9-11 [Link])

4. Install the timing belt tensioner and timing belt, and adjust the
timing belt tension. The engine section for procedures.
5. Install the timing belt covers.
6. Install the coolant pump pulley and drive belt, and then adjust the
belt tension.
7. Refill the system with clean coolant.
8. Run the engine and check for leaks.
 THERMOSTAT 25-15

THERMOSTAT

COMPONENTS

[N/A]

[T/C]
TORQUE : Nm ([Link], [Link])

REMOVAL AND INSPECTION

1. Drain the coolant down to thermostat level or below.
2. Remove the coolant outlet fitting and gasket.
3. Remove the thermostat.
4. Immerse the thermostat in hot water to check proper valve
opening temperature replace if necessary.

Valve opening temperature . . . . . . . . . . . . . . . . . 88ºC (190°F)

Full opening temperature . . . . . . . . . . . . . . . . . . 100ºC (212°F)

Valve lift (at full open) . . . . . . . . . . . . . . 8.5 mm (0.33 in.) or more

INSTALLATION
1. Check that the flange of the thermostat is correctly seated in the
socket of the thermostat housing. If the thermostat is installed
in the wrong direction, the bottom of the thermostat will touch the
rib inside the intake manifold, making it impossible for the
thermostat to operate properly.
2. Install a new gasket and the water outlet fitting.
3. Refill the system with clean coolant.
25-16 ENGINE COOLANT TEMPERATURE SENDER & ENGINE COOLANT TEMPERATURE SENSOR

ENGINE COOLANT TEMPERATURE SENDER & ENGINE COOLANT

TEMPERATURE SENSOR
COMPONENTS

Engine coolant temperature sensor

TORQUE : Nm ([Link], [Link])

REMOVAL
1. Drain the coolant down to sender level or below.
2. Disconnect the battery ground cable and disconnect the
engine harness connector from the sender & senser.
3. Remove the sender & sensor

INSPECTION
Engine coolant temperature sender
1. Heat the engine coolant temperature sender by submerging it
in hot water.
2. Check that the resistance is within the specified range.
Resistance . . . . . . . . . . . . . . . 90.5-117.5 i2 at 70°C (158°F)
21.3-26.3 Q at 115°C (239°F)
 COOLANT TEMPERATURE SENDER & COOLANT TEMPERATURE SENSOR 25-17

Coolant temperature sensor

1. Heat the sensor by submerging it in hot water.
2. Check that the resistance is within the specified range.

Resistance . . . . . . . . . . . . . . . . 2.27-2.73 KQ at 20°C (68°F)

290-354 !2 at 80°C (176°F)

INSTALLATION
1. Apply sealant to the threaded portion and tighten to the specified
torque.

Tightening torque
Engine coolant temperature sensor . . . . . . . . . . . . . .
10-12 Nm (100-120 [Link], 7.2-8.7 [Link])
Engine coolant temperature sensor .........................
20-40 Nm (200-400 [Link], 14-29 [Link])

2. Connect the harness connector to the engine coolant tempera-

ture sender, engine coolant temperature sensor.
3. Connect the battery ground cable.
4. Refill the system with clean coolant.
25-18 WATER HOSE AND PIPE

WATER HOSE AND PIPE

COMPONENTS
[N/A]

Exc. : Except
 WATER HOSE AND PIPE 25-19

INSPECTION
Check the water pipe and hoses for cracks, damage, or restrictions.
Replace if necessary.

INSTALLATION
1. Fit the O-ring in the groove provided at the water inlet pipe end,
wet the O-ring with water and insert the water inlet pipe.

NOTE
1. Do not apply oil or grease to the water pipe O-ring.
2. Keep the water pipe connections free of sand, dust, etc.
3. Insert the water pipe fully into the water pump.

2. Install the T/C cooling hoses (Refer 28 Group for detail)