ENGINE COOLING - Terios Club Italia · ENGINE COOLING COOLING SYSTEM (3SZ-VE) ... cylinder block and head. 2. ... around the radiator cap and water inlet. HINT:

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ENGINE

COOLING

COOLING SYSTEM (3SZ-VE)OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-1

COOLING SYSTEM (K3-VE)OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-3

COOLING FAN SYSTEM (3SZ-VE)OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-5LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6

COOLING FAN SYSTEM (K3-VE)OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-7LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-8

COOLANT (3SZ-VE)REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-9

COOLANT (K3-VE)REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-11

RADIATOR ASSEMBLY (3SZ-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-13REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-15INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-17

RADIATOR ASSEMBLY (K3-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-22INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-24

WATER PUMP ASSEMBLY (3SZ-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-27REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29

WATER PUMP ASSEMBLY (K3-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-31REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33

THERMOSTAT (3SZ-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-35REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-36INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-37INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-37

THERMOSTAT (K3-VE)COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-40REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-41INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-42INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-42

COOLING FAN RELAY (3SZ-VE)INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-45

TO INDEX

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COOLING FAN RELAY (K3-VE)INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-46

COOLING - COOLING SYSTEM (3SZ-VE) CO–1

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ENGINECOOLINGCOOLING SYSTEM (3SZ-VE)OPERATION CHECK1. CHECK FOR COOLANT LEAKS

CAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.Also be careful when applying the pressure to aradiator cap tester, as hot engine coolant from various parts ofthe cooling system may splash.

(a) Fill the radiator with coolant and attach a radiator cap tester.(b) Warm up the engine.(c) Using a radiator cap tester, increase the pressure inside the

radiator to 122.6 kPa (1.25 kgf/cm2), and check that thepressure does not drop.HINT:If the pressure drops, check the hose, radiator and water pumpfor leaks.If no external leaks are found, check the heater core,cylinder block and head.

2. CHECK COOLANT LEVEL(a) Check that the engine coolant level in the reserve tank is

between the LOW and FULL lines when the engine is cold.HINT:If the engine coolant is low, check for leaks and add coolant tothe FULL line.

3. CHECK COOLANT QUALITY(a) Remove the radiator cap.

CAUTION:Do not remove the radiator cap while the engine andradiator are still hot.Pressurized fluid and steam may bereleased and cause serious burns.

(b) Check if there are any excessive deposits of rust or scalesaround the radiator cap and water inlet.HINT:If excessively dirty, replace the coolant.

(c) Install the radiator cap.

4. CHECK RADIATOR CAP(a) If there are water stairs or foreign matter on packing 1, 2 or 3,

rinse them with water.NOTICE:Always clean by hand.

(b) Perform a visual check.(1) Check that there is no deformation, cracks or damage to

the metal, resin or rubber parts.(2) Check that there is no swelling on packing 1, 2 or 3.(3) Check that packing 3 and 4 are not stuck together.

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<2>

<3> <4>

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CO–2 COOLING - COOLING SYSTEM (3SZ-VE)

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(c) Perform a operation check.(1) Apply engine coolant to 2 and 3.(2) Using a radiator cap tester, measure the maximum

opening pressure while pumping the tester several time.Standard

NOTICE:When using the cap tester, tilt it more than 30degrees.HINT:If the maximum opening pressure is below the minimumstandard value, replace the radiator cap.

More Than 30°

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Standard 93.3 - 122.7 kPa (0.95 - 1.25 kgf/cm2)

Minimum StandardValue 78.5 kPa (0.8 kgf/cm2)

Measurement Condition Pumping speed is 1 turn within 1 second

COOLING - COOLING SYSTEM (K3-VE) CO–3

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ENGINECOOLINGCOOLING SYSTEM (K3-VE)OPERATION CHECK1. CHECK FOR COOLANT LEAKS

CAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.Also be careful when applying the pressure to aradiator cap tester, as hot engine coolant from various parts ofthe cooling system may splash.

(a) Fill the radiator with coolant and attach a radiator cap tester.(b) Warm up the engine.(c) Using a radiator cap tester, increase the pressure inside the




3. CHECK COOLANT QUALITY(a) Remove the radiator cap.

CAUTION:Do not remove the radiator cap while the engine andradiator are still hot.Pressurized fluid and steam may bereleased and cause serious burns.

(b) Check if there are any excessive deposits of rust or scalesaround the radiator cap and water inlet.HINT:If excessively dirty, replace the coolant.

(c) Install the radiator cap.

4. CHECK RADIATOR CAP(a) If there are water stairs or foreign matter on packing 1, 2 or 3,

rinse them with water.NOTICE:Always clean by hand.

(b) Perform a visual check.(1) Check that there is no deformation, cracks or damage to

the metal, resin or rubber parts.(2) Check that there is no swelling on packing 1, 2 or 3.(3) Check that packing 3 and 4 are not stuck together.

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CO–4 COOLING - COOLING SYSTEM (K3-VE)

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(c) Perform a operation check.(1) Apply engine coolant to 2 and 3.(2) Using a radiator cap tester, measure the maximum

opening pressure while pumping the tester several time.Standard

NOTICE:When using the cap tester, tilt it more than 30degrees.HINT:If the maximum opening pressure is below the minimumstandard value, replace the radiator cap.

More Than 30°

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Standard 93.3 - 122.7 kPa (0.95 - 1.25 kgf/cm2)

Minimum StandardValue 78.5 kPa (0.8 kgf/cm2)

Measurement Condition Pumping speed is 1 turn within 1 second

COOLING - COOLING FAN SYSTEM (3SZ-VE) CO–5

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ENGINECOOLINGCOOLING FAN SYSTEM (3SZ-VE)OPERATION CHECK1. CHECK OPERATION WHEN THE ENGINE IS COLD

(a) Make sure the coolant temperature is below 83°C (181.4°F).(1) Check that the cooling fan does not rotate when turning

the ignition switch to the ON position with the A/C switchOFF.

(2) Check that the cooling fan operates when the watertemperature sensor connector is disconnected and theignition switch is turned ON.

2. CHECK OPERATION WHEN ENGINE IS HOT(a) Make sure the coolant temperature is above 96°C (204.8 °F).

(1) After the engine is warmed up, check that the A/C isturned OFF.

(2) Check that the cooling fan starts rotating when the coolanttemperature reaches above 96°C (204.8°F) and that itstops rotating when the temperature reaches about94.5°C (202.1°F).NOTICE:The coolant temperature is detected by the watertemperature sensor on the water outlet (engine outlet)of the cylinder head.HINT:• The cleaning fan is controlled by the engine control

computer.• The coolant temperature can be checked using the

ECU DATA MONITOR on the DS-II.

CO–6 COOLING - COOLING FAN SYSTEM (3SZ-VE)

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LOCATION

ENGINE ROOM R/B

COOLING FAN RELAY

COOLING FAN MOTOR

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COOLING - COOLING FAN SYSTEM (K3-VE) CO–7

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ENGINECOOLINGCOOLING FAN SYSTEM (K3-VE)OPERATION CHECK1. CHECK OPERATION WHEN THE ENGINE IS COLD

(a) Make sure the coolant temperature is below 83°C (181.4° F).(1) Check that the cooling fan does not rotate when turning

the ignition switch to the ON position with the A/C switchOFF.

(2) Check that the cooling fan rotates when the watertemperature sensor connector is disconnected and theignition switch is turned ON.

2. CHECK OPERATION WHEN ENGINE IS HOT(a) Make sure the coolant temperature is above 96°C (204.8°F).

(1) After the engine is warmed up, check that the A/C isturned OFF.

(2) Check that the cooling fan starts rotating when the coolanttemperature reaches above 96°C (204.8°F) and that itstops rotating when the temperature reaches about94.5°C (202.1°F).NOTICE:The coolant temperature is detected by the watertemperature sensor on the water outlet (engine outlet)of the cylinder head.HINT:• The cleaning fan is controlled by the engine control

computer.• The coolant temperature can be checked using the

ECU DATA MONITOR on the DS-II.

CO–8 COOLING - COOLING FAN SYSTEM (K3-VE)

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LOCATION

ENGINE ROOM R/B

COOLING FAN RELAY

COOLING FAN MOTOR

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COOLING - COOLANT (3SZ-VE) CO–9

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ENGINECOOLINGCOOLANT (3SZ-VE)REPLACEMENT1. REMOVE ENGINE UNDER COVER

2. DRAIN ENGINE COOLANTCAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.(a) Open the radiator cap.(b) Loosen the radiator drain cock plug and drain the coolant.

3. ADD ENGINE COOLANT(a) Close the radiator drain cock plug.

Torque: 2.0 N*m (20 kgf*cm)

(b) Loosen the cock (white) of air bleed valves A and B to removethem.

(c) Pour coolant into the radiator inlet.(d) If the coolant overflows from air bleed valve A, tighten the cock

to valve A.[*1](e) If the coolant overflows from air bleed valve B, tighten the cock

to valve B.[*2](f) If the coolant overflows from the radiator, tighten the radiator

cap.(g) With the engine speed kept at 2,000 r/min, warm up the engine

until the coolant fan comes on two times. Then stop the engine.

Radiator Cap

Drain Cock

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Valve B

Valve A

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CO–10 COOLING - COOLANT (3SZ-VE)

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(h) After the engine has cooled down, pour coolant into the radiatorand reserve tanks.HINT:In operations [*1] and [*2], if coolant does not overflow fromeither air bleed valve A or valve B, or overflows from neithervalve A nor valve B, tighten the cocks to the air bleed valvesafter coolant overflows from the radiator.

4. CHECK FOR ENGINE COOLANT LEAKSCAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.(a) Fill the radiator with coolant and attach a radiator cap tester.(b) Using a radiator cap tester, increase the pressure inside the




6. INSTALL ENGINE UNDER COVER (See page CO-19)

COOLING - COOLANT (K3-VE) CO–11

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ENGINECOOLINGCOOLANT (K3-VE)REPLACEMENT1. REMOVE ENGINE UNDER COVER

2. DRAIN ENGINE COOLANTCAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.(a) Open the radiator cap.(b) Loosen the radiator drain cock plug and drain the coolant.

3. ADD ENGINE COOLANT(a) Close the radiator drain cock plug.


(b) Loosen the cock (white) of air bleed valves A and B to removethem.

(c) Pour coolant into the radiator inlet.(d) If the coolant overflows from air bleed valve A, tighten the cock

to valve A.[*1](e) If the coolant overflows from air bleed valve B, tighten the cock

to valve B.[*2](f) If the coolant overflows from the radiator, tighten the radiator

cap.(g) With the engine speed kept at 2,000 r/min, warm up the engine

until the coolant fan comes on two times. Then stop the engine.

Radiator Cap

Drain Cock

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Valve B

Valve A

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CO–12 COOLING - COOLANT (K3-VE)

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(h) After the engine has cooled down, pour coolant into the radiatorand reserve tanks.HINT:In operations [*1] and [*2], if coolant does not overflow fromeither air bleed valve A or valve B, or overflows from neithervalve A nor valve B, tighten the cocks to the air bleed valvesafter coolant overflows from the radiator.

4. CHECK FOR ENGINE COOLANT LEAKSCAUTION:Do not remove the radiator cap while the engine and radiator arestill hot.Pressurized fluid and steam may be released and causeserious burns.(a) Fill the radiator with coolant and attach a radiator cap tester.(b) Using a radiator cap tester, increase the pressure inside the





COOLING - RADIATOR ASSEMBLY (3SZ-VE) CO–13

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ENGINECOOLINGRADIATOR ASSEMBLY (3SZ-VE)COMPONENTS

×11

×2

T=7.5{76}

T=5.4{55}

AIR CLEANER HOSE NO. 1

ENGINE UNDER COVER

FRONT BUMPER COVER

FOG LIGHT ASSEMBLY RH

FOG LIGHT ASSEMBLY LH

TIGHTENING TORQUE [N*m{kgf*cm}].....A136654J01

CO–14 COOLING - RADIATOR ASSEMBLY (3SZ-VE)

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TIGHTENING TORQUE [N*m{kgf*cm}]

T=7.5{76}

T=7.5{76}

T=7.5{76}

T=7.5{76}

T=5.0{51}

×2

×2

×2

×2

×4

T=5.0{51}

T=5.0{51}T=5.0{51}

RADIATOR HOSE NO. 1

CHARCOAL CANISTER ASSEMBLY

WITH WATER FAN ASSEMBLY

RADIATOR SUPPORT CUSHION

DRAIN COCK SUB-ASSEMBLY

OIL COOLER OUTLET HOSE NO. 1


CONDENSER ASSEMBLY (WITH RESERVOIR)

SEAL PLATE

RADIATOR ASSEMBLY

OIL COOLER INLET HOSE NO. 1

RADIATOR CAP

RADIATOR HOSE NO. 2

CHARCOAL CANISTER NO. 1

RADIATOR RESERVE TANK ASSEMBLY

RADIATOR SUPPORT UPR

A/T

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REMOVAL1. DISCONNECT NEGATIVE BATTERY TERMINAL

(See page RS-164)

2. REMOVE ENGINE UNDER COVER

3. DRAIN ENGINE COOLANT (See page CO-9)

4. REMOVE FOG LIGHT ASSEMBLY LH (See page CO-9)

5. REMOVE FOG LIGHT ASSEMBLY RH

6. REMOVE FRONT BUMPER COVER (See page CO-15)

7. REMOVE AIR CLEANER HOSE NO. 1(a) Remove the 2 bolts. Then remove the air cleaner hose No. 1.

8. REMOVE SEAL PLATE(a) Detach the 2 clips and remove the seal plate.

9. REMOVE RADIATOR HOSE NO. 2(a) Remove the clip. Then radiator hose No. 2 hose.

10. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Remove the clip and disconnect oil cooler inlet hose No. 1 from

the radiator assembly.

11. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Remove the clip and disconnect oil cooler outlet hose No. 1

from the radiator assembly.

12. REMOVE RADIATOR RESERVE TANK ASSEMBLY(a) Disconnect the radiator reserve tank assembly hose.(b) Remove the bolt and pull out the pin on the lower side of the

radiator reserve tank assembly from the bush.

13. REMOVE RADIATOR HOSE NO. 1(a) Remove the clip. Then remove radiator hose No. 1.

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14. REMOVE CHARCOAL CANISTER ASSEMBLY(a) Remove the bolt. Then remove the charcoal canister pipe No. 1

from the battery carrier.

(b) Disconnect the 3 hoses and remove the charcoal canisterassembly from the bracket by sliding it upward.

15. REMOVE RADIATOR SUPPORT UPPER(a) Remove the bolt. Then remove the right and left radiator

support uppers.

16. REMOVE CONDENSER ASSEMBLY (WITH RECEIVER)(a) Remove the 4 bolts and disconnect the condenser assembly

(with receiver).

(b) Secure the condenser assembly (with receiver) to the radiatorsupport upper with a string so that it does not fall.

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17. REMOVE RADIATOR ASSEMBLY(a) Disconnect the cleaning fan motor connector and wire harness

clamp.(b) Remove the radiator assembly together with the with water fan

assembly from the vehicle.NOTICE:When removing the radiator assembly, do not applyunreasonable force to the condenser assembly (withreceiver) and the pipe.

18. REMOVE RADIATOR SUPPORT CUSHION

19. REMOVE WITH WATER FAN ASSEMBLY(a) Remove the 4 bolts and the with water fan assembly.

20. REMOVE DRAIN COCK SUB-ASSEMBLY(a) Remove the drain cock sub-assembly from the radiator

assembly.

INSTALLATION1. INSTALL DRAIN COCK SUB-ASSEMBLY

(a) Install the drain cock sub-assembly to the radiator assembly.

2. INSTALL WITH WATER FAN ASSEMBLY(a) Install the floor shift assembly with the 4 bolts.


3. INSTALL RADIATOR SUPPORT CUSHION

4. INSTALL RADIATOR ASSEMBLY(a) Install the radiator assembly to the vehicle together with the

cleaning fan assembly.NOTICE:Make sure the radiator assembly does not interfere with thecooler condenser assembly.

(b) Connect the cooling fan motor connector and the wire harnessclamp.

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5. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER)(a) Install the condenser assembly (with receiver) with the 4 bolts.


6. INSTALL RADIATOR SUPPORT UPPER(a) Install the radiator support upper with the bolt.


7. INSTALL CHARCOAL CANISTER ASSEMBLY(a) Install the 3 hoses.(b) Install the charcoal canister assembly to the bracket.

(c) Install the charcoal canister pipe No. 1 with the bolt.Torque: 7.5 N*m (76 kgf*cm)

8. INSTALL RADIATOR HOSE NO. 1(a) Install radiator hose No. 1 and fix it with the clamp.

9. INSTALL RADIATOR RESERVE TANK ASSEMBLY(a) Install the radiator reserve tank assembly with the bolt.

Torque: 7.5 N*m (76 kgf*cm)(b) Install the radiator reserve tank assembly hose.

10. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Install oil cooler outlet hose No. 1 and fix it with the clamp.

11. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Install oil cooler inlet hose No. 1 and fix it with the clamp.

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12. CONNECT RADIATOR HOSE NO. 2(a) Install radiator hose No. 2 and fix it with the clamp.

13. INSTALL SEAL PLATE(a) Install the seal plate with the 2 clips.

14. INSTALL AIR CLEANER HOSE NO. 1(a) Install the air cleaner hose No. 1 with the 2 bolts.



16. INSTALL FRONT BUMPER COVER (See page CO-19)

17. INSTALL FOG LIGHT ASSEMBLY LH

18. INSTALL FOG LIGHT ASSEMBLY RH

19. CONNECT NEGATIVE BATTERY TERMINALTorque: 5.4 N*m (55 kgf*cm)

20. REFILL ENGINE COOLANT (See page CO-10)

21. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10)

22. CHECK COOLANT LEVEL (See page CO-10)

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CO–20 COOLING - RADIATOR ASSEMBLY (K3-VE)

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ENGINECOOLINGRADIATOR ASSEMBLY (K3-VE)COMPONENTS

×11

×2

T=7.5{76}

T=5.4{55}


ENGINE UNDER COVER

FRONT BUMPER COVER

FOG LIGHT ASSEMBLY RH

FOG LIGHT ASSEMBLY LH

TIGHTENING TORQUE [N*m{kgf*cm}].....A136654J01

COOLING - RADIATOR ASSEMBLY (K3-VE) CO–21

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TIGHTENING TORQUE [N*m{kgf*cm}]

T=7.5{76}

T=7.5{76}

T=7.5{76}

T=7.5{76}

T=5.0{51}

×2

×2

×2

×2

×4

T=5.0{51}

T=5.0{51}T=5.0{51}

RADIATOR HOSE NO. 1

CHARCOAL CANISTER ASSEMBLY

WITH WATER FAN ASSEMBLY


DRAIN COCK SUB-ASSEMBLY

OIL COOLER OUTLET HOSE NO. 1


CONDENSER ASSEMBLY (WITH RESERVOIR)

SEAL PLATE

RADIATOR ASSEMBLY

OIL COOLER INLET HOSE NO. 1

RADIATOR CAP

RADIATOR HOSE NO. 2

CHARCOAL CANISTER NO. 1

RADIATOR RESERVE TANK ASSEMBLY

RADIATOR SUPPORT UPR

A/T

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REMOVAL1. DISCONNECT NEGATIVE BATTERY TERMINAL

(See page CO-22)

2. REMOVE ENGINE UNDER COVERó


4. REMOVE FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (Seepage LI-33)

5. REMOVE FOG LIGHT ASSEMBLY RH (WITH FOG LIGHT)

6. REMOVE FRONT BUMPER COVER (See page ET-2)

7. REMOVE AIR CLEANER HOSE NO. 1(a) Remove the 2 bolts. Then remove the air cleaner hose No. 1.

8. REMOVE SEAL PLATE(a) Detach the 2 clips and remove the seal plate.


10. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Remove the clip and disconnect the oil cooler inlet hose No. 1


11. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Remove the clip and disconnect oil cooler outlet hose No. 1


12. REMOVE RADIATOR RESERVE TANK ASSEMBLY(a) Disconnect the radiator reserve tank assembly hose.(b) Remove the bolt and pull out the pin on the lower side of the

radiator reserve tank assembly from the bush.


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14. REMOVE CHARCOAL CANISTER ASSEMBLY(a) Remove the bolt. Then remove the charcoal canister pipe No. 1

from the battery carrier.

(b) Disconnect the 3 hoses and remove the charcoal canisterassembly from the bracket by sliding it upward.

15. REMOVE RADIATOR SUPPORT UPPER(a) Remove the bolt. Then remove the right and left radiator

support uppers.

16. REMOVE CONDENSER ASSEMBLY (WITH RECEIVER)(a) Remove the 4 bolts and disconnect the condenser assembly

(with receiver).

(b) Secure the condenser assembly (with receiver) to the radiatorsupport upper with a string so that it does not fall.

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17. REMOVE RADIATOR ASSEMBLY(a) Disconnect the cleaning fan motor connector and wire harness

clamp.(b) Remove the radiator assembly together with the with water fan

assembly from the vehicle.NOTICE:When removing the radiator assembly, do not applyunreasonable force to the condenser assembly (withreceiver) and the pipe.

18. REMOVE RADIATOR SUPPORT CUSHION

19. REMOVE WITH WATER FAN ASSEMBLY(a) Remove the 4 bolts and the with water fan assembly.

20. REMOVE DRAIN COCK SUB-ASSEMBLY(a) Remove the drain cock sub-assembly from the radiator

assembly.

INSTALLATION1. INSTALL DRAIN COCK SUB-ASSEMBLY

(a) Install the drain cock sub-assembly to the radiator assembly.

2. INSTALL WITH WATER FAN ASSEMBLY(a) Install the floor shift assembly with the 4 bolts.


3. INSTALL RADIATOR SUPPORT CUSHION

4. INSTALL RADIATOR ASSEMBLY(a) Install the radiator assembly to the vehicle together with the

cleaning fan assembly.NOTICE:Make sure the radiator assembly does not interfere with thecooler condenser assembly.

(b) Connect the cooling fan motor connector and the wire harnessclamp.

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5. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER)(a) Install the condenser assembly (with receiver) with the 4 bolts.


6. INSTALL RADIATOR SUPPORT UPPER(a) Install the radiator support upper with the bolt.


7. INSTALL CHARCOAL CANISTER ASSEMBLY(a) Install the 3 hoses.(b) Install the charcoal canister assembly to the bracket.

(c) Install the charcoal canister pipe No. 1 with the bolt.Torque: 7.5 N*m (76 kgf*cm)

8. INSTALL RADIATOR HOSE NO. 1(a) Install radiator hose No. 1 and fix it with the clamp.

9. INSTALL RADIATOR RESERVE TANK ASSEMBLY(a) Install the radiator reserve tank assembly with the bolt.

Torque: 7.5 N*m (76 kgf*cm)(b) Install the radiator reserve tank assembly hose.

10. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Install oil cooler outlet hose No. 1 and fix it with the clamp.

11. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATICTRANSMISSION)(a) Install oil cooler inlet hose No. 1 and fix it with the clamp.

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12. CONNECT RADIATOR HOSE NO. 2(a) Install radiator hose No. 2 and fix it with the clamp.

13. INSTALL SEAL PLATE(a) Install the seal plate with the 2 clips.

14. INSTALL AIR CLEANER HOSE NO. 1(a) Install the air cleaner hose No. 1 with the 2 bolts.


15. INSTALL ENGINE UNDER COVER(a) Install the engine under cover with the 11 bolts.


16. INSTALL FRONT BUMPER COVER (See page ET-5)

17. INSTALL FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (Seepage LI-34)

18. INSTALL FOG LIGHT ASSEMBLY RH (WITH FOG LIGHT)

19. CONNECT NEGATIVE BATTERY TERMINALTorque: 5.4 N*m (55 kgf*cm)




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COOLING - WATER PUMP ASSEMBLY (3SZ-VE) CO–27

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ENGINECOOLINGWATER PUMP ASSEMBLY (3SZ-VE)COMPONENTS

TIGHTENING TORQUE

AIR CLEANER HOSE NO. 1T=7.5{76}

FAN AND ALTERNATOR V BELT

T=5.4{55} ×11

ENGINE UNDER COVER

A136710J01

CO–28 COOLING - WATER PUMP ASSEMBLY (3SZ-VE)

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T=9.0{92}

T=9.0{92}

T=11.5{117}

×4

WATER PUMP ASSEMBLY FAN PULLEY

WATER PUMP GASKET

TIGHTENING TORQUE NON-REUSEABLE PARTA136711J01

COOLING - WATER PUMP ASSEMBLY (3SZ-VE) CO–29

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REMOVAL1. REMOVE ENGINE UNDER COVER


3. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15)

4. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)

5. REMOVE FAN PULLEY(a) Using a screwdriver or similar, fix the fan pulley, as shown in the

illustration to prevent it from being turned.(b) Remove the 3 bolts. Then remove the fan pulley.

6. REMOVE WATER PUMP ASSEMBLY(a) Remove the 3 bolts and 2 nuts. Then remove the water pump.

INSPECTION

1. WATER PUMP ASSEMBLY(a) Check that there is no looseness and abnormal sound on the

bearings.

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY(a) Using a new gasket, install the water pump with the 3 bolts and

2 nuts.Torque: 9.0 N*m (92 kgf*cm)NOTICE:Make sure there is no oil on the bolt threads.

2. INSTALL FAN PULLEY(a) Temporarily install the fan pulley with the 3 bolts.

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(b) Using a screwdriver or similar, fix the fan pulley, as shown in theillustration to prevent it from being turned. Then install it.

(c) Tighten the 3 bolts.Torque: 11.5 N*m (117 kgf*cm)

3. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)

4. ADJUST FAN AND ALTERNATOR V BELT (See page EM-9)

5. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)




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COOLING - WATER PUMP ASSEMBLY (K3-VE) CO–31

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ENGINECOOLINGWATER PUMP ASSEMBLY (K3-VE)COMPONENTS

TIGHTENING TORQUE

AIR CLEANER HOSE NO. 1T=7.5{76}

FAN AND ALTERNATOR V BELT

T=5.4{55} ×11

ENGINE UNDER COVER

A136710J01

CO–32 COOLING - WATER PUMP ASSEMBLY (K3-VE)

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T=9.0{92}

T=9.0{92}

T=11.5{117}

×4

WATER PUMP ASSEMBLY FAN PULLEY

WATER PUMP GASKET

TIGHTENING TORQUE NON-REUSEABLE PARTA136711J01

COOLING - WATER PUMP ASSEMBLY (K3-VE) CO–33

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2. DRAIN ENGINE COOLANT(See page CO-11)


4. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)

5. REMOVE FAN PULLEY(a) Using a screwdriver or similar, fix the fan pulley, as shown in the

illustration to prevent it from being turned.(b) Remove the 3 bolts. Then remove the fan pulley.

6. REMOVE WATER PUMP ASSEMBLY(a) Remove the 3 bolts and 2 nuts. Then remove the water pump.

INSPECTION

1. WATER PUMP ASSEMBLY(a) Check that there is no looseness and abnormal sound on the

bearings.

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY(a) Using a new gasket, install the water pump with the 3 bolts and

2 nuts.Torque: 9.0 N*m (92 kgf*cm)NOTICE:Make sure there is no oil on the bolt threads.

2. INSTALL FAN PULLEY(a) Temporarily install the fan pulley with the 3 bolts.

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(b) Using a screwdriver or similar, fix the fan pulley, as shown in theillustration to prevent it from being turned. Then install it.

(c) Tighten the 3 bolts.Torque: 11.5 N*m (117 kgf*cm)

3. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)

4. ADJUST FAN AND ALTERNATOR V BELT (See page EM-9)

5. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)




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COOLING – THERMOSTAT (3SZ-VE) CO–35

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ENGINECOOLINGTHERMOSTAT (3SZ-VE)COMPONENTS

TIGHTENING TORQUE [N*m {kgf*cm}].....

T=7.5{76}

T=7.5{76}

T=9.0{92}T=18{184}

T=5.4{55}

AIR CLEANER ASSEMBLY

WATER INLETTHERMISTOR


ENGINE UNDER COVER

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CO–36 COOLING – THERMOSTAT (3SZ-VE)

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4. REMOVE AIR CLEANER ASSEMBLY (See page EM-173)

5. REMOVE WATER INLET(a) Remove the bolt. Then remove the harness clamp.

(b) Disconnect the connector.

(c) Remove the bolt. Then remove the harness clamp.(d) Disconnect the connector.

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(e) Remove the bolt and the nut. Then remove the water inlet.

6. REMOVE THERMOSTAT(a) Remove the thermostat.

INSPECTION1. THERMOSTAT

(a) Before heating, measure the dimension with the valve fullyclosed.

(b) Immerse the thermostat in water and gradually heat the water.(c) Check the valve opening temperature.

Standard:78 - 82°C

HINT:• The thermostat is stamped with the valve opening

temperature. • If the valve opening temperature is not as specified, replace

the thermostat.

(d) Check the valve lift.Standard:

Valve lift 8.5 mm or moreTemperature with the valve fully open 93°C

HINT:If the valve lift is not as specified, replace the thermostat.

(e) Check that the valve is fully closed when the thermostat is atlow temperature (below 75°C/167°F).HINT:If the valve is not fully closed, replace the thermostat.

INSTALLATION1. INSTALL THERMOSTAT

(a) Install a new thermostat gasket to the thermostat.

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(b) Install the thermostat, aligning the water inlet matchmark andthe thermostat jiggle valve.

2. INSTALL WATER INLET(a) Using a pri set torque wrench, install the water inlet with the bolt

and nut.Torque: 9.0 N*m (92 kgf*cm)

(b) Connect the connector.

(c) Install the wire harness clamp with the bolt.

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(d) Install the wire harness clamp with the bolt.

(e) Install the wire harness clamp with the bolt.(f) Connect the connector.

3. INSTALL AIR CLEANER ASSEMBLY (See page EM-194)

4. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26)





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ENGINECOOLINGTHERMOSTAT (K3-VE)COMPONENTS

TIGHTENING TORQUE [N*m {kgf*cm}].....

T=7.5{76}

T=7.5{76}

T=9.0{92}T=18{184}

T=5.4{55}

AIR CLEANER ASSEMBLY

WATER INLETTHERMISTOR


ENGINE UNDER COVER

A138914J01

COOLING - THERMOSTAT (K3-VE) CO–41

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4. REMOVE AIR CLEANER ASSEMBLY (See page EM-173)

5. REMOVE WATER INLET(a) Remove the bolt. Then remove the harness clamp.

(b) Disconnect the connector.

(c) Remove the bolt. Then remove the harness clamp.(d) Disconnect the connector.

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(e) Remove the bolt and the nut. Then remove the water inlet.

6. REMOVE THERMOSTAT(a) Remove the thermostat.

INSPECTION1. THERMOSTAT

(a) Before heating, measure the dimension with the valve fullyclosed.

(b) Immerse the thermostat in water and gradually heat the water.(c) Check the valve opening temperature.

Standard:78 - 82°C

HINT:• The thermostat is stamped with the valve opening

temperature. • If the valve opening temperature is not as specified, replace

the thermostat.

(d) Check the valve lift.Standard:

Valve lift 8.5 mm or moreTemperature with the valve fully open 93°C

HINT:If the valve lift is not as specified, replace the thermostat.

(e) Check that the valve is fully closed when the thermostat is atlow temperature (below 75°C/167°F).HINT:If the valve is not fully closed, replace the thermostat.

INSTALLATION1. INSTALL THERMOSTAT

(a) Install a new thermostat gasket to the thermostat.

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More Than 8.5 mm

Length When Fully Open A134293

COOLING - THERMOSTAT (K3-VE) CO–43

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(b) Install the thermostat, aligning the water inlet matchmark andthe thermostat jiggle valve.

2. INSTALL WATER INLET(a) Using a pri set torque wrench, install the water inlet with the bolt

and nut.Torque: 9.0 N*m (92 kgf*cm)

(b) Connect the connector.

(c) Install the wire harness clamp with the bolt.

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(d) Install the wire harness clamp with the bolt.

(e) Install the wire harness clamp with the bolt.(f) Connect the connector.

3. INSTALL AIR CLEANER ASSEMBLY (See page EM-194)

4. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26)




8. INSTALL ENGINE UNDER COVER (See page EM-104)

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ENGINECOOLINGCOOLING FAN RELAY (3SZ-VE)INSPECTION1. RADIATOR FAN RELAY

(a) Check the continuity.(1) Using the tester, check the continuity between each of the

connecter terminals.Standard:

1 terminal ←→ 2 terminal: continuity3 terminal ←→ 5 terminal: no continuity

(2) Using the tester, check the continuity between terminal 3and 5 when battery voltage is applied to terminal 1 and 2. Standard:

ContinuityA133875

CO–46 COOLING - COOLING FAN RELAY (K3-VE)

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ENGINECOOLINGCOOLING FAN RELAY (K3-VE)INSPECTION1. RADIATOR FAN RELAY

(a) Check the continuity.(1) Using the tester, check the continuity between each of the

connecter terminals.Standard:

1 terminal ←→ 2 terminal: continuity3 terminal ←→ 5 terminal: no continuity

(2) Using the tester, check the continuity between terminal 3and 5 when battery voltage is applied to terminal 1 and 2.Standard:

ContinuityA133875

TO INDEX TO NEXT SECTION

Documents

ENGINE COOLING - Terios Club Italia · ENGINE COOLING COOLING SYSTEM (3SZ-VE) ... cylinder block and head. 2. ... around the radiator cap and water inlet. HINT: