Engine Cooling - honda-stream.ru - Cooling System.pdf · ＊01 SJC8A00A14400000000DAAT00 10-2 Cooling System Component Location Index RADIATOR CAP RADIATOR

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Engine Cooling

Cooling System

Fan Controls

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Component Location Index . 10-2Radiator Cap Test . 10-3Radiator Test . 10-3Fan Motor Test . 10-4Thermostat Test . 10-4Water Pump Inspection . 10-5Water Pump Replacement . 10-5Coolant Check . 10-6Coolant Replacement . 10-6Thermostat Replacement . 10-8Water Passage Replacement . 10-9Radiator and Fan Replacement . 10-12

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Component Location Index . 10-15Symptom Troubleshooting Index . 10-16Circuit Diagram . 10-17Radiator Fan High Speed Circuit Troubleshooting . 10-18

07/05/09 16:41:59 61SJC020_100_0001

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10-2

Cooling System

Component Location Index

RADIATOR CAP

RADIATOR

WATER PASSAGE

THERMOSTAT

WATER PUMP

RADIATOR FAN ASSEMBLY

Test,page 10-3

Replacement, page 10-12


Test, page 10-4Replacement, page 10-8

Inspection, page 10-5Replacement, page 10-5

Replacement, page 10-12Fan Motor Test, page 10-4

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10-310-3

Radiator Cap Test Radiator Test

B

A

A

1. Remove the radiator cap (A). Wet its seal withengine coolant, then install it on a commerciallyavailable pressure tester (B).

2. Apply a pressure of 93 123 kPa (0.951.25 kgf/cm , 14 18 psi).

3. Check for a drop in pressure.

4. If the pressure drops, replace the cap.

1. Wait until the engine is cool, then carefully removethe radiator cap, and fill the radiator with enginecoolant to the top of the filler neck.

2. Attach a commercially available pressure tester (A)to the radiator, and apply a pressure of 93 123 kPa(0.95 1.25 kgf/cm , 14 18 psi).

3. Inspect for engine coolant leaks and a drop inpressure.

4. Remove the tester, then reinstall the radiator cap.

2

2

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Standard Thermostat

Lift Height: Above 10.0 mm (0.39 in.)

Starts Opening: 169 176 °F (76 80 °C)

Fully Open: 194 °F (90 °C)

10-410-4

Cooling System

Fan Motor Test Thermostat Test

A B

B

A

1. Disconnect the 2P connectors from the radiator fanmotor (A) and condenser fan motor (B).

2. Test each motor by connecting battery power to theNo. 1 terminal and ground to the No. 2 terminal.

3. If either motor fails to run or does not run smoothly,replace it (see page 10-12).

Replace the thermostat if it is in the stuck open positionat room temperature.

To test a closed thermostat:

1. Suspend the thermostat (A) in a container of water.Do not let the thermometer (B) touch the bottom ofthe hot container.

2. Heat the water and check the temperature with athermometer. Note the temperature at which thethermostat first opens, and at which it is fully open.

3. Measure the lift height of the thermostat when it isfully open.

Terminal side ofmale terminals

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10-510-5

Water Pump Inspection Water Pump Replacement

A

A

6 x 1.0 mm12 N·m(1.2 kgf·m, 8.7 lbf·ft)

A

B

1. Remove the timing belt (see page 6-13).

2. Turn the water pump pulley counterclockwise.Check that it turns freely. If it doesn’t turn smoothly,replace the water pump (see page 10-5).

NOTE: When you check the water pump, you maysee a small amount of ‘‘weeping’’ from the bleedholes (A). This is normal.

3. Install the timing belt (see page 6-16).

1. Drain the engine coolant (see page 10-6).

2. Remove the timing belt (see page 6-13).

3. Remove the timing belt adjuster (see page 6-24).

4. Remove the water pump (A) by removing the fivebolts.

5. Inspect and clean the O-ring groove and the matingsurface of the engine block.

6. Install the water pump with a new O-ring (B) in thereverse order of removal.

7. Clean up any spilled engine coolant.

8. Install the timing belt adjuster (see page 6-24).

9. Install the timing belt (see page 6-16).

10. Refill the radiator with engine coolant, then bleedthe air from the cooling system (see step 9 on page10-7).

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10-610-6

Cooling System

Coolant Check Coolant Replacement

B

A

A

B9.8 N·m(1.0 kgf·m, 7.2 lbf·ft)

A

1. Look at the coolant level in the coolant reservoir.Make sure it is between the MAX mark (A) and MINmark (B).

2. If the coolant level in the coolant reservoir is at orbelow the MIN mark, add coolant to bring itbetween the MIN and MAX marks, then inspect thecooling system for leaks.

1. Start the engine. Set the heater temperature controldial to maximum heat, then turn off the ignitionswitch. Make sure the engine and radiator are coolto the touch.

2. Remove the radiator cap.

3. Remove the splash shield (see step 30 on page 5-5).

4. Loosen the drain plug (A), and drain the coolant.

5. Install a rubber hose (A) on the drain bolt (B)located at the rear of the engine block, then loosenthe drain bolt.

6. When the coolant stops draining, tighten the drainbolt. Remove the rubber hose.

7. Tighten the radiator drain plug securely.

8. Install the splash shield (see step 31 on page 5-17).

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Engine Coolant Capacities (Including the reserve

tank capacity of 0.6 L (0.16 US gal)):

After Coolant Change: 6.2 L (1.64 US gal)

After Engine Overhaul: 8.1 L (2.14 US gal)

10-7

A

9. Remove, drain, and reinstall the reserve tank.

10. Fill the reserve tank to the MAX mark (A) withHonda Long Life Antifreeze/Coolant Type 2 (P/NOL999-9001).

11. Pour Honda Long Life Antifreeze/Coolant Type 2into the radiator up to the base of the filler neck.

NOTE:• Always use Honda Long Life Antifreeze/Coolant

Type 2 (P/N OL999-9001). Using a non-Hondacoolant can result in corrosion, causing thecooling system to malfunction or fail.

• Honda Long Life Antifreeze/Coolant Type 2 is amixture of 50 % antifreeze and 50 % water. Donot add water.

12. Install the radiator cap loosely.

13. Start the engine and let it run until it warms up (theradiator fan comes on at least twice).

14. Turn off the engine. Check the level in the radiatorand add Honda Long Life Antifreeze/Coolant Type 2,if needed.

15. Put the radiator cap on tightly, then run the engineagain, and check for leaks.


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10-8

Cooling System

Thermostat Replacement

PIN

THERMOSTAT COVER

GROUND CABLE

RUBBER SEAL

THERMOSTAT

6 x 1.0 mm12 N·m(1.2 kgf·m, 8.7 lbf·ft)

1.


3. Remove the ground cable and thermostat cover, then remove the thermostat.

4. Install the new thermostat with a new rubber seal.

5. Refill the radiator with engine coolant, then bleed air from the cooling system (see step 9 on page 10-7).


Replace.

Install with pin up.

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Disconnect the breather pipe, then remove the air intake duct (see step 9 on page 5-2).

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10-9

Water Passage Replacement

A

B

A B C

D

A

B


2. Remove the intake manifold (see page 9-3).

3. Remove the upper radiator hose (A) and lowerradiator hose (B).

4. Remove the water bypass hose (A) and groundcable (B).

5. Remove the harness holder mounting bolt (C), thenremove the harness holder (D) from the bracket.

6. Remove the heater hoses.

7. Remove the engine wire harness connectors fromthe water passage.

• Engine coolant temperature (ECT) sensor 1connector

• Engine coolant temperature (ECT) sensor 2connector

• Exhaust gas recirculation (EGR) valve connector

8. Remove the water passage (A) and connecting pipe(B).

(cont’d)

07/05/09 16:42:04 61SJC020_100_0009

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10-10

Cooling System

Water Passage Replacement (cont’d)

A

D

F

G

E

H

6 x 1.0 mm12 N·m(1.2 kgf·m, 8.7 lbf·ft)

I

H

8 x 1.25 mm22 N·m(2.2 kgf·m, 16 lbf·ft)

B12 N·m(1.2 kgf·m, 8.7 lbf·ft)

C12 N·m(1.2 kgf·m, 8.7 lbf·ft)

B

A

D

8 x 1.25 mm22 N·m(2.2 kgf·m, 16 lbf·ft)

C

C

9. Remove the EGR valve (A), ECT sensor 1 (B), ECTsensor 2 (C), thermostat cover (D), and thermostat(E).

10. Install the new rubber seal (F) onto the thermostat,then install the thermostat with pin (G) up, andinstall the thermostat cover.

11. Install the ECT sensor 1 and ECT sensor 2, using thenew O-rings (H).

12. Install the EGR valve, using a new gasket (I).

13. Install the connecting pipe (A) and water passage(B), using the new O-rings (C) and new gaskets (D).

14. Install the heater hoses.

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10-11

C D

A

6 x 1.0 mm12 N·m(1.2 kgf·m, 8.7 lbf·ft)

B6 x 1.0 mm12 N·m(1.2 kgf·m, 8.7 lbf·ft)

A

B

15. Install harness holder (A) to the bracket, thentighten the mounting bolt (B).

16. Install the water bypass hose (C) and ground cable(D).

17. Install the upper radiator hose (A) and lowerradiator hose (B).

18. Install the intake manifold (see page 9-5).

19. After installation, check that all tubes, hoses andconnectors are installed correctly.

20. Refill the radiator with engine coolant, then bleedair from the cooling system (see step 9 on page10-7).


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10-12

Cooling System

Radiator and Fan Replacement

A

C

A

B

B

A

B


2. Remove the front air intake duct.

3. Remove the bulkhead cover.

4. Disconnect the fan motor connectors (A), thenremove the harness clamps (B) and reservoir tankhose (C).

5. Remove the upper radiator hose (A) and lowerradiator hose (B).

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10-13

A

B

A

A B A

6. Remove the splash shield.

7. Remove the automatic transmission fluid (ATF)cooler hoses (A) from the radiator, then plug theline and hose.

8. Unclamp the ATF cooler hoses clamp (B) on theATF cooler line.

9. Remove the harness clamps (A) and A/Ccompressor clutch connector (B) from the A/Ccondenser fan shroud.

(cont’d)

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10-14

Cooling System

Radiator and Fan Replacement (cont’d)

UPPER RADIATOR HOSE

LOWER RADIATOR HOSE

RADIATOR FAN SHROUD

RADIATOR FAN MOTOR

A/C CONDENSER FAN/SHROUD ASSEMBLY

RADIATOR FAN

LOWER CUSHION

RADIATOR

DRAIN PLUG

RESERVE TANK

UPPER BRACKETAND CUSHION

RADIATOR CAP

6 x 1.0 mm9.8 N·m(1.0 kgf·m, 7.2 lbf·ft)

6.0 N·m(0.61 kgf·m, 4.4 lbf·ft)

6 x 1.0 mm7.1 N·m(0.72 kgf·m, 5.2 lbf·ft)

6 x 1.0 mm7.1 N·m(0.72 kgf·m, 5.2 lbf·ft)

O-RING

10. Remove the upper bracket cushions, then pull up the radiator.

11. Remove the fan shroud assemblies and other parts from the radiator.

12. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely.

13. Fill the radiator with engine coolant, then bleed air from the cooling system (see step 9 on page 10-7).

Replace.

07/05/09 16:42:07 61SJC020_100_0014

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10-15

Fan Controls

Component Location Index

AUXILIARY UNDER-HOOD RELAY BOX

A/C CONDENSER FANRELAY

RADIATOR FAN RELAY

FAN CONTROL RELAY

A/C CONDENSER FANASSEMBLY

ENGINE COOLANTTEMPERATURE (ECT)SENSOR 1

RADIATOR FAN ASSEMBLY

ENGINE COOLANTTEMPERATURE (ECT)SENSOR 2

Test, page 22-75

Test, page 22-75

Test, page 22-75

Motor Test, page 10-4


Motor Test, page 10-4


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Symptom Diagnostic Procedure Also check for

10-16

Fan Controls

Symptom Troubleshooting Index

••

Engine overheats 1.2.

3.

4.5.6.

7.8.9.10.

11.12.

Check the coolant level.

A/C condenser.

Check for damaged or deformed fan shroud.Inspect the fan motors (see page 10-4) or fanrelays (see page 22-75).Check the radiator cap (see page 10-3).Check the thermostat (see page 10-4).Inspect the water pump (see page 10-5).Check for a plugged or deteriorated radiatorhoses.Check for plugged heater core or hoses.Check for a damaged cylinder head gasket.

The radiator fan runs at low speed,but it does not run at high speedwhen the engine coolanttemperature is above 206 °F(97 °C)

Radiator fan high speed circuit troubleshooting(see page 10-18).

Cleanliness andtightness of allconnectors

With the A/C off and the enginecoolant temperature at 206 °F(97 °C) or below, the A/Ccondenser fan runs at high speedand the radiator fan does not run.When the engine coolanttemperature is above 206 °F(97 °C), both fans run at highspeed

Remove the fan control relay, and test.If the relay is faulty, replace it.If the relay is OK, check for a short in the wirebetween fan control relay 5P socket terminal No. 1and condenser fan motor 2P connector terminalNo. 1.


The radiator fan runs at highspeed with the ignition switch ON(II), the A/C off, and the enginecoolant temperature below 204 °F(95 °C)

Check for a short in the wire between radiator fanrelay 4P socket terminal No. 3 and PCM connectorterminal A5.


Both the radiator fan and the A/Ccondenser fan run at low speedwith the ignition switch ON (II)and the A/C off

Check for a short in the wire between A/C condenserfan relay 4P socket terminal No. 3 and PCM connectorterminal A4.


Both the radiator fan and the A/Ccondenser fan do not run at lowspeed with the A/C on

Radiator and A/C condenser fans low speed circuittroubleshooting (see page 21-40).


The A/C condenser fan does notrun at all. The radiator fan doesnot run at low speed, but it runs athigh speed

A/C condenser fans high speed circuittroubleshooting (see page 21-44).


Both the radiator fan and the A/Ccondenser fan do not run at highspeed when the engine coolanttemperature is above 206 °F(97 °C)

Check for an open in the wire between radiator fanrelay 4P socket terminal No. 3 and PCM connectorterminal A5.


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Check for any engine coolant leaks(from gaskets, hoses, O-rings, etc.).

Check for deteriorated coolant.

Check for dirt, leaves, or insects on radiator and

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10-17

Circuit Diagram

TW SG2 TW2

MRLYFANLFANH

D7X1D16

A4D10

D2 D5

E6

G1

YEL/GRNYEL

PCM

GRN

BLU/BLK

BLK/YEL

WHT/RED

YEL

YEL

No.23(7.5 A)

WHT/GRN

WHTBLK/YEL

No.8 (15 A)

GRN/REDGRN/YELRED/WHT

C27 C14 C36

A6A5 A4

5 V

YEL/WHT RED/YEL

(7.5 A)No.30

IG2 HOT in ON (III)

2 3

41

GRN/YEL

2 3

41

G201

GRN

BLK

1 5

4 2 3

GRN

BLU/BLK

1

2

1

2

No.23 (IG) (50 A)

BLU/YEL

UNDER HOOD FUSE/RELAY BOX

BATTERY

IGNITION SWITCH

BLK/YEL

G201

No.22 (BAT) (120 A)

BLU/BLK

BLK

No.19 (30 A) No.20 (30 A)

RADIATORFANMOTOR

FANCONTROLRELAY

A/CCONDENSERFANMOTOR

PGM FIMAINRELAY 1

RADIATORFANRELAY

A/CCONDENSERFANRELAY

ENGINE COOLANTTEMPERATURE(ECT) SENSOR 1

ENGINE COOLANTTEMPERATURE(ECT) SENSOR 2

UNDER DASHFUSE/RELAYBOX

AUXILIARYUNDER HOOD RELAY BOX

42

IG2

BAT

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－

－

－

－

－

－

－

－

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

10-18

Fan Controls

Radiator Fan High Speed Circuit Troubleshooting

RADIATOR FAN RELAY 4P SOCKET


JUMPER WIRE


1. Check the No. 19 (30 A) fuse in the under-hoodfuse/relay box, and the No. 23 (7.5 A) fuse in theunder-dash fuse/relay box.

Go to step 2.

Replace the fuse(s) and recheck.

2. Remove the radiator fan relay from the auxiliaryunder-hood relay box and test it (see page 22-75).

Go to step 3.

Replace the radiator fan relay.

3. Measure the voltage between the radiator fan relay4P socket terminal No. 1 and the body ground.

Go to step 4.

Repair open in the wire between radiator fanrelay 4P socket terminal No. 1 and the under-hoodfuse/relay box.

4. Connect radiator fan relay 4P socket terminalsNo. 1 and No. 2 with a jumper wire.

Go to step 5.

Repair open in the wire between the radiatorfan relay 4P socket terminal No. 2 and radiator fanmotor 2P connector terminal No. 2.

5. Turn the ignition switch ON (II).

6. Measure voltage between radiator fan relay 4Psocket terminal No. 4 and the body ground.

Repair open in the wire between the radiatorfan relay 4P socket terminal No. 3 and thepowertrain control module (PCM) (A5).

Repair open in the wire between the radiatorfan relay 4P socket terminal No. 4 and the under-dash fuse/relay box.

Terminal side of female terminals



Are the fuses OK ?

Is the relay OK ?

Is there battery voltage?

Does the radiator fan run at high speed?

Is there battery voltage?

07/05/09 16:42:10 61SJC020_100_0018

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Engine Cooling - honda-stream.ru - Cooling System.pdf · ＊01 SJC8A00A14400000000DAAT00 10-2 Cooling System Component Location Index RADIATOR CAP RADIATOR