Application	Description	Unit	Standard
Cooling System	Cooling Type	-	Forced Water Cooling
Coolant	Coolant Capacity	L/qt	7.5 / 7.93
Termostat	Thermostat Type	-	Wax Expansion Pellet Type
	Temperature(opened initially)	°C (°F)	83~87(181.4~188.6)
	Temperature(perfectly opened)	°C (°F)	100 (212)
	Temperature(perfectly closed)	°C (°F)	78 ~ 82 (172.4 ~ 179.6)
	Stroke(perfectly opened)	mm (in.)	8 (0.315)
Electric Cooling Fan	Cooling Fan type	-	Electric
	Blade Number	EA	5
	Cooling Fan Diameter	mm (in.)	320(12.600)
	Temperature At Low Speed ON	°C (°F)	96 (204.8)
	Temperature At Low Speed OFF	°C (°F)	94.5 (202.1)
	Temperature At High Speed ON	°C (°F)	99 (210.2)
	Temperature At High Speed OFF	°C (°F)	97.5 (207.52)
Termostat	Open Pressure of The Pressure Valve	kPa(psi)	117.7~147.1(17.07~21.34)
	Open Pressure of The Vacuum Valve	°C (°F)	9.8(1.42)
Coolant Pump	Water Pump Type	-	Centrifugal
	Impeller Diameter	mm (in.)	65(2.56)
	Impeller Blade Number	EA	6
Radiator	Radiator Type	-	Down Flow
	Core Width	mm (in.)	701(27.60)
	Core Height	mm (in.)	372(14.65)
	Core Depth	mm (in.)	18(0.71)

Application	N•m	Lb-Ft	Lb-In
Coolant Pump Mounting Bolts	20	15	-
Coolant Temperature Sensor	20	15	-
Fan Assembly Mounting Bolts	4	-	35
Fan Motor Nut	3.2	-	28
Fan Motor Retaining Screws	4	-	35
Radiator Retaining Bolts	4	-	35
Surge Tank Attaching Bolt	8	-	71
Thermostat Housing Mounting Bolts	15	11	-
Transaxle Fluid Cooler Pipe Bolt	2.5	-	22

KM-471 Adapter

1. Remove the thermostat from the vehicle. Refer to "Thermostat" in this section.
2. Make sure the valve spring is tight when the thermostat is closed. If the spring is not tight, replace the thermostat.
3. Suspend the thermostat and a thermometer in a pan of 50/50 mixture of ethylene glycol and water. Do not let the thermostat or the thermometer rest on the bottom of the pan. The uneven concentration of heat on the bottom could result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of the heated solution.
6. The thermostat should begin to open at 87°C (189°F) and it should be fully open at 102°C (216°F). If it does not open at these temperatures, replace the thermostat.

1. Wash any sludge from the surge tank cap and the valve seat of the vacuum pressure valve for the surge tank cap.
2. Check for any damage or deformity to the vacuum pressure valve for the surge tank cap. If any damage or deformity is found, replace the cap.
3. Install a suitable cooling system pressure tester to the cap using the adapter KM-471.
4. Pull the vacuum pressure valve open. If the surge tank cap does not seal properly, replace the surge tank cap.
5. Pressurize the cap to 90 to 120 kPa (13 to 17 psi).
6. Wait 10 seconds and check the pressure held by the tank cap tester.

1. If the pressure held by the cooling system pressure tester falls below 80 kPa (11.6 psi), replace the surge tank cap

Checks	Action
Check for a loss of the coolant.	Add the coolant.
Check for a weak coolant solution.	Confirm that the coolant solution is a 50/50 mixture of ethylene glycol and water.
Check the front of the radiator for any dirt, any leaves, or any insects.	Clean the front of the radiator.
Check for leakage from the hoses, the coolant pump, the heater, the thermostat housing, the radiator, the core plugs, or the head gasket.	Replace any damaged components.
Check for a faulty thermostat.	Replace a damaged thermostat.
Check for retarded ignition timing.	Perform an ECM code diagnosis. Confirm the integrity of the timing belt.
Check for an improperly operating electric cooling fan.	Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.	Replace any damaged radiator hoses.
Check for a faulty water pump.	Replace a faulty water pump.
Check for a faulty surge tank cap.	Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is cracked or plugged.	Repair the damaged cylinder head or the damaged engine block.

Checks	Action
Check for a leak in the radiator.	Replace a damaged radiator.
Check for a leak in the following locations: Surge tank. Hose.	Replace the following parts, as needed: Surge tank. Hose.
Check for loose or damaged radiator hoses, heater hoses, and connections.	Reseat the hoses. Replace the hoses or the clamps.
Check for leaks in the coolant pump seal.	Replace the coolant pump seal.
Check for leaks in the coolant pump gasket.	Replace the coolant pump gasket.
Check for an improper cylinder head torque.	Tighten the cylinder head bolts to specifications. Replace the cylinder head gasket, if needed.
Check for leaks in the following locations: Intake manifold. Cylinder head gasket. Cylinder block plug. Heater core. Radiator drain plug.	Repair or replace any components, as needed, to correct the leak.

Checks	Action
Check to determine if the thermostat is stuck open or is the wrong type of thermostat.	Install a new thermostat of the correct type and heat range.
Check the coolant level to determine if it is below the MIN mark on the surge tank.	Add sufficient coolant to raise the fluid to the specified mark on the surge tank.

1. Upper Radiator Bumper
2. Radiator Bracket
3. Radiator Retaining Bolts
4. Radiator
5. Radiator Bumper
6. Spring Clamp
7. Upper Radiator Hose
8. Fan Assembly Mounting Bolts
9. Drain Plug
10. Cooling Fan Assembly
11. Cooling Fan

1. O-Ring Seal
2. Thermostat
3. Thermostat Housing
4. Thermostat Housing Mounting Bolt
5. Coolant Pump Mounting Bolt
6. Coolant Pump
7. Ring Seal

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Caution : Do not remove the surge tank cap while the engine and the radiator are hot. Scalding fluid and steam may be blown out under pressure.
1. Place a pan below the vehicle to catch the draining coolant.
2. Remove the surge tank cap.
3. Unplug the drain plug.



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Caution : Dispose of the used coolant in a used coolant holding tank to be picked up with the used oil for disposal. Never pour the used coolant down the drain. Ethylene glycol antifreeze is an extremely toxic chemical. Disposing of it into the sewer system or the ground water can contaminate the local environment.
4. Catch the escaping fluid in a drain pan.
5. Remove all sludge and dirt from inside the surge tank. Refer to "Surge Tank" in this section.
6. Screw in the drain plug.
7. Add clean water to the surge tank.
8. Fill the tank slowly so that the upper reservoir hose remains above the water line. This allows the air inside the cooling system to escape.
9. Start the engine.
10. Run the engine until the thermostat opens. You can tell the thermostat is open when both radiator hoses are hot to the touch.



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11. Stop the engine.
12. Repeat steps 1 through 9 until the drained water is clear and free of coolant and rust.
Notice : Never use an antifreeze mixture more concentrated than 60 percent antifreeze to 40 percent water. The solution freezing point increases above this concentration.
13. Fill the cooling system through the surge tank with a mixture of ethylene glycol antifreeze and water. The mixture must be at least 50 percent antifreeze, but not more than 60 percent antifreeze.
14. Fill the surge tank to the specified MAX fill mark on the outside of the tank.

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Caution : To prevent personal injury, do not remove the surge tank cap while the engine and the radiator are hot because the heat causes the system to remain under pressure. Scalding fluid and steam may be blown out under pressure.
1. Drain the coolant. Refer to "Draining and Refilling the Cooling System" in this section.
2. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
3. Disconnect the upper radiator hose from the thermostat housing.



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4. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
5. Remove the thermostat housing from the cylinder head.



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6. Remove the O-ring seal from the thermostat housing.
7. Remove the thermostat from the thermostat housing by pressing the thermostat mounting flange downward and then rotating the flange clockwise.
8. Inspect the valve seat for foreign matter that could prevent the valve from sealing properly.
9. Inspect the thermostat for proper operation. Refer to "Thermostat Test" in this section.
10. Clean the thermostat housing and the cylinder head mating surfaces.

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1. Install the thermostat into the thermostat housing by pressing the thermostat mounting flange downward and then rotating the flange counterclockwise. Rotate the thermostat mounting flange until it is seated in the thermostat housing recesses.
2. Coat the sealing surface of the new O-ring seal with Lubriplate®.
3. Install the new O-ring seal into the recess in the thermostat housing.



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4. Install the thermostat housing to the cylinder head.
5. Secure the thermostat housing to the cylinder head with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 15 N•m (11 lb-ft).




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6. Connect the upper radiator hose to the thermostat housing.
7. Secure the upper radiator hose to the thermostat housing with a hose clamp.
8. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.

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1. Drain the engine cooling system to a level below the thermostat housing. Refer to "Draining and Refilling the Cooling System" in this section.
2. Remove the timing belt. Refer to Section 1C, DOHC Engine Mechanical.
3. Remove the timing belt tension roller retaining bolt.
4. Remove the timing belt tension roller.



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5. Remove the coolant pump mounting bolts.
6. Remove the coolant pump from the engine block.
7. Remove the ring seal from the coolant pump.

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1. Inspect the coolant pump body for cracks and leaks.
2. Inspect the coolant pump bearing for play or abnormal noise.
3. Inspect the coolant pump pulley for excessive wear. If the coolant pump is defective, replace the coolant pump as a unit.
4. Clean the mating surfaces of the coolant pump and the engine block.

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1. Install a new ring seal to the coolant pump.
2. Coat the sealing surface of the ring seal with Lubriplate®.
3. Install the coolant pump to the engine block with the flange aligned with the recess of the rear timing belt cover.
4. Secure the coolant pump to the engine block with the mounting bolts.
Tighten
Tighten the coolant pump mounting bolts to 20 N•m (15 lb-ft).




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5. Install the timing belt tension roller to the oil pump with the flange inserted into the recess of the oil pump.
6. Install the timing belt tension roller bolt. Do not tighten the bolt at this time.
7. Install the timing belt. Refer to Section 1C, DOHC Engine Mechanical.
8. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.

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1. Disconnect the negative battery cable.
2. Remove the bolts with the snorkel.
3. Disconnect the cooling fan electrical connector.
4. Remove the fan shroud mounting bolts.
5. Lift the fan shroud assembly upward, and remove the fan shroud assembly from the vehicle.



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6. Remove the nuts with the fan blade from the fan shroud assembly.



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7. Remove the fan motor retaining screws.
8. Remove the fan motor from fan blade.

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Caution : If a fan blade is bent or damaged in any way, no attempt should be made to repair or reuse the damaged part. A bent or damaged fan assembly must be replaced with a new fan assembly. It is essential that fan assemblies remain in proper balance. A fan assembly that is not in proper balance can fail and fly apart during use, creating extreme danger. Proper balance cannot be assured on a fan assembly that has been bent or damaged.
1. Install the fan motor to the shroud.
2. Secure the motor to the shroud with the retaining screws.
Tighten
Tighten the fan motor retaining screws to 4 N•m (35 lb-in).




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3. Install the fan to the fan shroud assembly with the single nut in the center of the fan hub.
Tighten
Tighten the fan motor nut to 3.2 N•m (28 lb-in).




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4. Install the fan shroud assembly to the radiator.
Important : Be careful to seat the mounting post on the fan shroud into the socket at the radiator left tank. Be sure to slip the tab at the bottom edge of the shroud into the retaining clip near the center of the radiator.
5. Secure the shroud to the top of the radiator with the mounting bolts.
Tighten
Tighten the fan assembly mounting bolts to 4 N•m (35 lb-in).


6. Connect the cooling fan electrical connector.
7. Install the snorkel with the mounting bolts.
Tighten
Tighten the snorkel mounting bolts to 6 N•m (53 lb-in).


8. Connect the negative battery cable.

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Caution : To prevent personal injury, do not remove the surge tank cap while the engine and the radiator are hot, because the heat causes the system to remain under pressure. Scalding fluid and steam may be blown out under pressure.
1. Drain the engine coolant to below the level of the surge tank.
2. Loosen the return hose clamp and disconnect the return hose from the top of the surge tank.
3. Loosen the throttle body hose clamp and disconnect the throttle body hose from the top of the surge tank.
4. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.
5. Remove the surge tank attaching bolt.
6. Remove the surge tank from the support mount.
7. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
8. Rinse the surge tank and the cap thoroughly.

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1. Install the surge tank to the support mount.
2. Secure the surge tank with the attaching bolt.
Tighten
Tighten the surge tank attaching bolt to 8 N•m (71 lb-in).


3. Connect the return hose and the throttle body hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps.
6. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.

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1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.
3. Remove the main and the auxiliary cooling fans. Refer to "Electric Cooling Fan - Main or Auxiliary" in this section.
4. Remove the lower radiator hose clamp.
5. Disconnect the lower radiator hose from the radiator.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radiator.



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8. Remove the hose clamp from the surge tank hose at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Disconnect the transaxle fluid cooler pipes from the lower radiator tank, if equipped.
11. Remove the bolt and the transaxle fluid cooler pipe support clamp from the radiator.
12. Remove the left upper radiator retaining bolt.
13. Remove the left upper radiator retaining bracket.



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14. Remove the right upper radiator retaining bolt.
15. Remove the right upper radiator retaining bracket.
16. Remove the radiator from the vehicle.
Important : The radiator still contains a substantial amount of coolant. Drain the remainder of the coolant from the radiator into a drain pan.

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1. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.



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2. Position the radiator retainers in place.
3. Install the right upper radiator retainer bracket.
4. Install the right upper radiator retaining bolt.
Tighten
Tighten the right upper radiator retaining bolt to 4 N•m (35 lb-in).




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5. Install the left upper radiator retainer bracket.
6. Install the left upper radiator retaining bolt.
Tighten
Tighten the left upper radiator retaining bolt to 4 N•m (35 lb-in).




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7. Connect the transaxle fluid cooler pipes to the lower radiator tank, if equipped.
8. Install the transaxle fluid cooler pipe and support clamp to the radiator with a bolt.
Tighten
Tighten the transaxle fluid cooler pipe bolt to 2.5 N•m (22 lb-in).


9. Connect the surge tank hose to the radiator.
10. Secure the surge tank hose with a hose clamp.
11. Connect the upper radiator hose and the lower ra-diator hose to the radiator.
12. Secure each hose with a hose clamp.
13. Install the main and the auxiliary cooling fans. Refer to "Electric Cooling Fan-Main or Auxiliary" in this section.
14. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.
15. Connect the negative battery cable.

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1. Disconnect the negative battery cable.
2. Drain the coolant to a level below the coolant temperature sensor.
3. Disconnect the electrical connector from the coolant temperature sensor.
4. Remove the temperature sensor.

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1. Install the coolant temperature sensor into the threaded hole in the EGR valve mounting adapter.
Tighten
Tighten the coolant temperature sensor to 20 N•m (15 lb-ft).


2. Connect the electrical connector to the coolant temperature sensor.
3. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.
4. Connect the negative battery cable.

• The cooling fans are actuated by the engine control module (ECM) using a low-speed cooling fan relay and a high-speed cooling fan relay and a series/parallel cooling fan relay.
• The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 93°C (199°F) and at high speed when the coolant temperature reaches 97°C (207°F).
• The ECM will change the cooling fans from high speed to low speed at 94°C (201°F) and will turn the cooling fans off at 90°C (194°F).