Application	Description	Unit	Standard
Cooling System	Cooling Type	-	T/Belt Drive & Forced Water Cooling
Coolant	Capacity	L/qt	5.2L (5.5 qt) : 1.2 SOHC 7.0L (7.48 qt) : 1.4 SOHC/DOHC, 1.5 SOHC
Thermostat	Thermostat Type	-	Wax Expainsion Pellet Type
	Temperature (Opened Initially)	°C (°F)	87 (189)
	Temperature (Perpectly Opened)	°C (°F)	102 (216)
	Temperature (Perpectly Closed)	°C (°F)	82 (180)
	Stroke (Perpectly Opened)	mm (in)	7 (0.28)
Surege Tank Cap	Open Pressure of the Pressure Valve	kPa (psi)	120 - 150 (17.4 - 21.8)
	Open Pressure of the Vacuum Valve	kPa (psi)	10 (1.5)
Coolant Pump	Water Pump Type	-	T/Belt Drived Centrifugal
	Impeller Diameter	mm (in)	55 (2.17)
	Impeller Blade Number	EA	55 (2.17)

Application	N•m	Lb-Ft	Lb-In
Coolant Pump Mounting Bolts	10	-	89
Electric Cooling Fan Motor Nut	3.2	-	28
Electric Cooling Fan Motor Retaining Screws	4	-	35
Electric Cooling Fan Assembly Mounting Bolts	4	-	35
Engine Coolant Temperature Sensor	20	15	-
Negative Battery Terminal Retainer Bolt	15	11	-
Surge Tank Attaching Bolt	10	-	89
Thermostat Housing Mounting Bolts	20	15	-
Upper Left Radiator Retaining Bolt	10	-	89
Upper Right Radiator Retaining Bolt	10	-	89

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 fully 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 because 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 KM-471 adapter.
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 to120 to 160 kPa (17 to 23 psi).
6. Wait 10 seconds and check the pressure held by the tank cap tester.

7. If the pressure held by the cooling system pressure tester falls below 80 kPa (16 psi) replace the surge tank cap.
8. If the pressure held by the cooling system pressure tester falls below 80 kPa (16 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 a code diagnosis using the engine control module (ECM) for a vehicle with a manual transaxle. 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.	Replace a faulty water pump.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: Surge tank. Hose.
Check for the following loose or damaged parts: Radiator hoses. Heater hoses. 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 if it 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. Bolt
2. Cooling Fan
3. Radiator
4. Upper Radiator Hose
5. Spring Clamp
6. Radiator Bumper
7. Radiator Bracket
8. Drain Cock
9. Bolt

1. Bolt
2. Cooling Fan
3. Radiator
4. Upper Radiator Hose
5. Spring Clamp
6. Radiator Bumper
7. Radiator Bracket
8. Drain Cock
9. Bolt

1. Bolt
2. Cooling Fan
3. Radiator
4. Upper Radiator Hose
5. Spring Clamp
6. Radiator Bumper
7. Radiator Bracket
8. Drain Cock
9. Bolt

1. Thermostat Housing Bolt
2. Thermostat Housing
3. Thermostat
4. Coolant Pump Mounting Bolt
5. Coolant Pump Mounting Nut
6. Coolant Pump
7. Coolant Pump Gasket

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

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

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Caution : To avoid injury, 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 cock.



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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. Plug the drain cock.
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 : To avoid damaging the vehicle, 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 for cold weather operation.
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. Remove the timing belt rear hood. Refer to Section 1B2, SOHC Engine Mechanical.
3. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
4. Disconnect the upper radiator hose from the thermostat housing.



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5. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
6. Remove the thermostat housing from the cylinder head.
7. Remove the thermostat from its recess in the cylinder head.
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 cylinder head recess.
2. Install the thermostat housing.
3. Secure the thermostat housing to the cylinder head with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20 N•m (15 lb-ft).


4. Install the timing belt rear Hood. Refer to Section 1B2, SOHC Engine Mechanical.
5. Connect the upper radiator hose to the thermostat housing.
6. Secure the upper radiator hose to the thermostat housing with a hose clamp.
7. 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 rear hood. Refer to Section 1B2, SOHC Engine Mechanical,
3. Remove the coolant pump mounting bolts.
4. Remove the coolant pump from the cylinder block.
5. 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 cylinder 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.
4. Secure the coolant pump to the engine block with the mounting bolts.
Tighten
Tighten the coolant pump mounting bolts to 10 N•m (89 lb-in).


5. Install the rear timing belt rear hood. Refer to Section 1B2, SOHC Engine Mechanical.
6. 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. Disconnect the cooling fan electrical connector.



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3. Remove the electric cooling Fan Mounting bolts.
4. Remove the electric cooling Fan.

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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 electric cooling fan.
2. Install the electric cooling Fan Mounting bolts.
Tighten
Tighten the electrical cooling fan moumting bolts to 4 N•m (35 lb-in).




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3. Connect the cooling fan electriceal connector

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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 overflow hose clamps and disconnect the overflow hose from the top of the surge tank.
3. Remove the tank attaching nuts.
4. Remove the tank from the vehicle.
5. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
6. Rinse the surge tank and the cap thoroughly.

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1. Install the surge tank to the vehicle.
2. Secure the surge tank with the attaching nuts.
Tighten
Tighten the surge tank attaching nuts to 10 N•m (89 lb-in).


3. Connect the overflow hose to the surge tank.
4. Secure the overflow hose to the surge tank with the hose clamps.
5. 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 electric cooling fans. Refer to "Electric Cooling Fan" in this section.
4. Remove the upper radiator hose clamp.
5. Disconnect the upper radiator hose from the radiator.



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6. Disconnect the lower radiator hose from the radiator.
7. Remove the lower radiator hose clamp.



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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. Remove the left upper radiator retaining bolt.
11. Remove the left upper radiator retaining bracket.



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12. Remove the right upper radiator retaining bolt.
13. Remove the right upper radiator retaining bracket.



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14. 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 rediator bottom posts in the rubber shock bumpers.



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2. Position the radiator retainers in place.
3. Install the upper right radiator retaining bracket.
4. Install the upper right radiator retaining bolt.
Tighten
Tighten the upper right radiator retaining bolt to 10 N•m (89 lb-in).




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5. Install the upper left radiator retaining bracket.
6. Install the upper left radiator retaining bolt.
Tighten
Tighten the upper lef radiator retaining bolt to 10 N•m (89 lb-in).




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7. Connect the surge tank hose to the radiator.
8. Secure the surge tank hose with a hose clamp.



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9. Connect the upper radiator hose and the lower radiator hose to the radiator.
10. Secure each hose with a hose clamp.
11. Install the electric cooling fans. Refer to "Electric Cooling Fan" in this section.
12. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in this section.
13. Connect the negative battery cable.

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

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1. Install the coolant temperature sensor into the threaded hole in the cylinder head.
Tighten
Tighten the coolant temperature sensor to 20 N•m (15 lb-ft).


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

• The cooling fan(s) are actuated by the powertrain control module (PCM) in vehicles with an automatic transaxle or the engine control module (ECM) using a low-speed cooling fan relay and a high-speed cooling fan relay. On A/C-equipped vehicles, a series/parallel cooling fan relay is also used.
• The PCM or the ECM will turn the cooling fan(s) on at low speed when the coolant temperature reaches 93°C (199°F) and high speed at 97°C (207°F).
• The PCM or the ECM will change the cooling fan(s) from high speed to low speed at 94°C (201°F) and turn the cooling fans off at 90°C (194°F).

• The PCM or the ECM will turn the cooling fans on at low speed when the A/C system is on. The PCM or the ECM will change to high speed when the coolant temperature reaches 97°C (207°F) or high-side A/C pressure reaches 1 882 kPa (273 psi).
• The cooling fans will return to low speed when the coolant temperature reaches 94°C (201°F) or high-side A/C pressure reaches 1 448 kPa (210 psi).