Cooling - Lancer Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air. The water pump is of the centrifugal type and is driven by the drive belt from the crankshaft. The radiator is the corrugated fin, down flow type.

Scheme 1

Scheme 2

SPECIAL TOOLS

SPECIAL TOOLS TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MB991871 LLC changer General service tool Coolant refilling MB991223 MB991219 MB991220 MB991221 MB991222 Harness set Test harness LED harness LED harness adapter Probe General service tools Making voltage and resistance measurement during troubleshooting Connector pin contact pressure inspection Power circuit inspection Power circuit inspection Commercial tester connection MB992006 Extra fine probe General service tool Making voltage and resistance measurement during troubleshooting

Scheme 3

Scheme 4

Scheme 5

INTRODUCTION

The system cools the engine so that it does not overheat and maintains the engine at an optimum temperature. The system components are the radiator, water pump, thermostat, condenser fan assembly. Possible faults include low coolant, contamination, belt loosening and component damage.

TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure to find most of the engine cooling faults.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find and repair the malfunction by following the SYMPTOM CHART.
4. Verify that the malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

Scheme 6

1. STEP 1. Check for coolant leaks. WARNING: When pressure testing the cooling system, slowly release cooling system pressure to avoid getting burned by hot coolant. CAUTION: Be sure to completely clean away any moisture from the places checked. When the tester is removed, be careful not to spill any coolant. When installing and removing the tester and when testing, be careful not to deform the filler neck of the radiator. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa (23 psi) pressure, and then check for leakage from the radiator hose or connections. Q: Is leakage present from the radiator hose or connections? YES : Repair or replace the appropriate part, then go to Step 2. NO : There is no action to be taken.
2. STEP 2. Retest the system. Q: It there still coolant leakage? YES : Return to Step 1 . NO : The procedure is complete.

Scheme 7

1. STEP 1. Remove the radiator cap and check for coolant contamination. Q: Is the coolant contaminated with rust and oil? YES : Replace it. Refer to «ENGINE COOLANT REPLACEMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer__engine-coolant-replacement) . NO : There is no action to be taken. Go to Step 2.
2. STEP 2. Check the radiator cap valve opening pressure. NOTE: Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading. Use a cap adapter to attach the cap to the tester. Increase the pressure until the gauge indicator stops moving. Minimum limit: 83 kPa (12 psi) Standard value: 93 - 123 kPa (14 - 18 psi) Q: Does the reading remain at or above the minimum limit? YES : Go to Step 3. NO : Replace the radiator cap. Then go to Step 5 .
3. STEP 3. Check thermostat operation. Refer to «THERMOSTAT CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer) . Q: Does the thermostat operate correctly? YES : Go to Step 4. NO : Replace the thermostat, then go to Step 5 .
4. STEP 4. Check the drive belt for slippage or damage. Refer to «8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) . Q: Is the drive belt loose or damaged? YES : Adjust or replace the drive belt, then go to Step 5. NO : There is no action to be taken.
5. STEP 5. Retest the system. Check the coolant temperature. Q: Is the coolant temperature abnormally high? YES : Return to Step 2 . NO : The procedure is complete.

Scheme 8

Scheme 9

Scheme 10

CIRCUIT OPERATION

1. The fan control module is powered from fusible link number 2.
2. The ECM < M/T > or PCM < A/T > judges the required revolution speed of radiator fan motor and condenser fan motor using the input signals transmitted from A/C switch, automatic compressor controller, vehicle speed sensor and engine coolant temperature sensor. The ECM < M/T > or PCM < A/T > activates the fan control module to drive the radiator fan motor and condenser fan motor.

TECHNICAL DESCRIPTION

1. The cause could be a malfunction of the fan control module power supply or ground circuit.
2. The cause could also be a malfunction of the fan control module or the EC < M/T > or PCM < A/T >.

TROUBLESHOOTING HINTS

1. Malfunction of fusible link
2. Malfunction of fan control relay
3. Malfunction of MFI relay
4. Malfunction of radiator fan motor
5. Malfunction of condenser fan motor
6. Malfunction of fan control module
7. Malfunction of ECM < M/T > or PCM < A/T >
8. Damaged wiring harness or connector

DIAGNOSIS

Required Special Tools

1. MB991223: Harness Set
2. MB992006: Extra Fine Probe

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. STEP 1. Check the circuit at fan control module connector A-17 (terminal 3). Disconnect fan control module connector A-17, and measure at the harness side connector. Measure the voltage between terminal number 3 and ground. When the ignition switch is turned to the "ON" position, voltage should measure battery positive voltage. Q: Is there voltage battery positive voltage when the ignition switch is turned to the "ON" position? YES : Go to Step 8 . NO : Go to Step 2.
2. STEP 2. Check the fan control relay. Refer to «FAN CONTROL RELAY CONTINUITY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer__fan-control-relay-continuity-check) . Q: Is the fan control relay in good condition? YES : Go to Step 3. NO : Replace it, then go to Step 1.
3. STEP 3. Check the MFI relay. Refer to «MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/removal-installation/#multiport-fuel-injection-mfi-lancer-20l) . Q: Is the MFI relay in good condition? YES : Go to Step 4. NO : Replace it, then go to Step 1 .
4. STEP 4. Check for harness damage between fusible link number 2 and fan control relay connector A-09X (terminal 4). Q: Are the harness wires between fusible link number 2 and fan control relay connector A-09X damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 5.
5. STEP 5. Check for harness damage between fan control relay connector A-09X (terminal 2) and fan control module connector A-17 (terminal 3). Q: Are the harness wires between fan control relay connector A-09X (terminal 2) and fan control module connector A-17 (terminal 3) damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 6.
6. STEP 6. Check for harness damage between MFI relay connector B-16X and fan control relay connector A-09X. NOTE: After inspecting intermediate connector A-13 terminal 8 and joint connector C-105 terminal 28, 33 inspect the wires. If intermediate connector A-13 and joint connector C-105 are damaged, repair or replace them. Refer to «HARNESS CONNECTOR INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/body-electrical/#general-electrical-lancer) . Q: Are the harness wires between MFI relay connector B-16X (terminal 4) and fan control relay connector A-09X (terminal 1) damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 7.
7. STEP 7. Check for harness damage between fan control relay connector A-09X (terminal 3) and ground. Q: Are the harness wires between fan control relay connector A-09X (terminal 3) and ground damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 8.
8. STEP 8. Check the circuit at fan control module connector A-17 (terminal 1). Disconnect fan control module connector A-17, and measure at the harness side connector. Measure the resistance between terminal number 1 and ground. Q: Is the resistance less than 2 ohms? YES : Go to Step 10 . NO : Go to Step 9.
9. STEP 9. Check the harness wire between fan control module connector A-17 and ground. Q: Are the harness wires between fan control module connector A-17 and ground damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 10.
10. STEP 10. Measure the output circuit voltage at ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > by backprobing. Do not disconnect ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17)< 2.4L-A/T >. Start the engine and allow it to idle. Measure the voltage between terminal number 18 < 2.0L > or 17 < 2.4L > and ground by backprobing. Q: Is the voltage 0.7 volt or more when the radiator fan is operating? YES : Go to Step 12 . NO : Go to Step 11.
11. STEP 11. Check the harness wire between ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > and fan control module connector A-17. NOTE: If intermediate connector A-13 terminal 1 is damaged, repair or replace it. Refer to «HARNESS CONNECTOR INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/body-electrical/#general-electrical-lancer) . Q: Are the harness wires between ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > and fan control module connector A-17 (terminal 2) damaged? YES : Repair or replace them, then go to Step 13 . NO : Go to Step 12.
12. STEP 12. Check the fan control module at ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T >. Disconnect ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T >. Turn the ignition switch to the "ON" position. Q: Do the radiator fan motor and condenser fan motor operate? YES : Replace the ECM < M/T > or PCM < A/T >. Then go to Step 13. NO : Replace the fan control module. Then go to Step 13.
13. STEP 13. Check the symptoms. Q: Do the radiator fan and condenser fan operate correctly? YES : The procedure is complete. NO : Return to Step 1 .

INSPECTION PROCEDURE 4: Radiator Fan and Condenser Fan do not Change Speed or Stop

Note. If the engine coolant temperature reaches 110°C (230°F) or higher, the radiator fan control runs the radiator fan for up to 5 minutes even after the ignition switch is turned to the "LOCK" (OFF) position [the fan stops its rotation when the engine coolant temperature decreases to 110°C (230°F) or lower.]

RADIATOR FAN AND CONDENSER FAN DRIVE CIRCUIT

Refer to INSPECTION PROCEDURE 3: RADIATOR FAN AND CONDENSER FAN DO NOT OPERATE .

1. The fan control module is powered from fusible link number 2.
2. The ECM < M/T > or PCM < A/T > judges the required revolution speed of radiator fan motor and condenser fan motor using the input signals transmitted from A/C switch, automatic compressor controller, vehicle speed sensor and engine coolant temperature sensor. The ECM < M/T > or PCM < A/T > activates the fan control module to drive the radiator fan motor and condenser fan motor.

1. The fan control module has variable control of the radiator fan motor and the condenser fan motor speeds using signals transmitted from the ECM < M/T > or PCM < A/T >.

1. Malfunction of fan control relay
2. Malfunction of fan control module
3. Malfunction of ECM < M/T > or PCM < A/T >

Required Special Tools

1. MB991223: Harness Set
2. MB992006: Extra Fine Probe

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. STEP 1. Check the fan control relay. Refer to «FAN CONTROL RELAY CONTINUITY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer__fan-control-relay-continuity-check) . Q: Is the fan control relay in good condition? YES : Go to Step 2. NO : Replace the part, then go to Step 6 .
2. STEP 2. Check the harness wire between fan control relay connector A-09X (terminal 2) and fan control module connector A-17 (terminal 3). Q: Are the harness wire between fan control relay connector A-09X and fan control module connector A-17 damaged? YES : Repair or replace the part, then go to Step 6 . NO : Go to Step 3.
3. STEP 3. Measure the output circuit voltage at ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > by backprobing. Do not disconnect ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17)< 2.4L-A/T >. Start the engine and run it at idle. [Engine coolant temperature: 80°C (176°F) or less] Measure the voltage between terminal number 18 < 2.0L > or 17 < 2.4L > and ground by backprobing. Q: Is the voltage 0 - 0.3 volt when the radiator fan is not operating? YES : Go to Step 6 . NO : Go to Step 4.
4. STEP 4. Check the harness wire between ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > and fan control module connector A-17. NOTE: If intermediate connector A-13 terminal 1 is damaged, repair or replace it. Refer to «HARNESS CONNECTOR INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/body-electrical/#general-electrical-lancer) . Q: Are the harness wires between ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > and fan control module connector A-17 damaged? YES : Repair or replace them, then go to Step 6 . NO : Go to Step 5.
5. STEP 5. Check the fan control module at ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T >. Disconnect ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T >. Pull out the pin 18 < 2.0L > or 17 < 2.4L > and connect it to the body ground. Reconnect ECM connector C-119 (terminal 18) < 2.0L-M/T >, C-133 (terminal 17) < 2.4L-M/T > or PCM connector C-120 (terminal 18) < 2.0L-A/T >, C-134 (terminal 17) < 2.4L-A/T > with pin 18 < 2.0L > or 17 < 2.4L > still removed. Turn the ignition switch to the "ON" position. Q: Do the radiator fan motor and condenser fan motor stop? YES : Replace the ECM < M/T > or PCM < A/T >. Then go to Step 6. NO : Replace the fan control module. Then go to Step 6.
6. STEP 6. Check the symptoms. Q: Do the radiator fan and condenser fan operate correctly? YES : The procedure is complete. NO : Return to Step 1 .

Refer to INSPECTION PROCEDURE 3: RADIATOR FAN AND CONDENSER FAN DO NOT OPERATE .

1. The fan control module is powered from fusible link number 2.
2. The ECM < M/T > or PCM < A/T > judges the required revolution speed of radiator fan motor and condenser fan motor using the input signals transmitted from A/C switch, automatic compressor controller, vehicle speed sensor and engine coolant temperature sensor. The ECM < M/T > or PCM < A/T > activates the fan control module to drive the radiator fan motor and condenser fan motor.

The cause could be a malfunction of the radiator fan motor or an open circuit between the fan control module and the radiator fan motor.

1. Malfunction of radiator fan motor
2. Malfunction of fan control module

1. STEP 1. Check the radiator fan motor. Refer to «RADIATOR FAN MOTOR CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer) . Q: Is the radiator fan in good condition? YES : Go to Step 2. NO : Replace the radiator fan motor, then go to Step 3 .
2. STEP 2. Check the fan control module. Refer to «FAN CONTROL MODULE CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer) . Q: Is the fan control module in good condition? YES : Go to Step 3. NO : Replace the fan control module, then go to Step 3.
3. STEP 3. Check the symptoms. Q: Does the radiator fan operate correctly? YES : The procedure is complete. NO : Return to Step 1 .

Refer to INSPECTION PROCEDURE 3: RADIATOR FAN AND CONDENSER FAN DO NOT OPERATE .

1. The fan control module is powered from fusible link number 2.
2. The ECM < M/T > or PCM < A/T > judges the required revolution speed of radiator fan motor and condenser fan motor using the input signals transmitted from A/C switch, automatic compressor controller, vehicle speed sensor and engine coolant temperature sensor. The ECM < M/T > or PCM < A/T > activates the fan control module to drive the radiator fan motor and condenser fan motor.

The cause could be a malfunction of the condenser fan motor or fan control module.

1. Malfunction of condenser fan motor
2. Malfunction of fan control module

1. STEP 1. Check the condenser fan motor. Refer to «CONDENSER FAN MOTOR CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/ac-compressor/#heater-air-conditioning-and-ventilation-lancer__condenser-fan-motor-check) . Q: Is the condenser fan motor in good condition? YES : Go to Step 2. NO : Replace the condenser fan motor, then go to Step 3 .
2. STEP 2. Check the fan control module. Refer to «FAN CONTROL MODULE CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/cooling-system-mechanical/#cooling-lancer) . Q: Is the fan control module in good condition? YES : Go to Step 3. NO : Replace the fan control module, then go to Step 3.
3. STEP 3. Check the symptoms. Q: Does the condenser fan operate correctly? YES : The procedure is complete. NO : Return to Step 1 .

ENGINE COOLANT LEAK CHECK

1. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa (23 psi) pressure, and then check for leakage from the radiator hose or connections.
2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE CHECK

Note. Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading.

1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving. Minimum limit: 83 kPa (12 psi) Standard value: 93 - 123 kPa (14 - 18 psi)
3. Replace the radiator cap if the reading does not remain at or above the limit.

ENGINE COOLANT REPLACEMENT

Required Special Tool

1. MB991871: LLC Changer

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain the coolant.
4. Drain the cooling water then clean the path of the cooling water by injecting water into the radiator from the radiator cap area.
5. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque. Specified sealant: 3M™ AAD Part No.8731 or equivalent Tightening torque: < 2.0L Engine > 40+/-5 N.m (30+/-3 ft-lb) < 2.4L Engine > 44+/-5 N.m (33+/-3 ft-lb)
6. Securely tighten the drain plug of the radiator.
7. Assemble the radiator condenser tank. CAUTION: Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminum components.
8. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60 %. Use special tool MB991871 to refill the coolant. A convenient mixture is a 50 % water and 50 % antifreeze solution [freezing point: -31°C (-32.8°F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: < 2.0L Engine > 6.0 dm 3 (6.3 quarts) < 2.4L Engine > 7.0 dm 3 (7.4 quarts) NOTE: For how to use special tool MB991871, refer to its manufacturer's instructions.
9. Reinstall the radiator cap.
10. Start the engine and let it warm up until the thermostat opens.
11. After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
12. Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap. CAUTION: Do not overfill the reserve tank.
13. Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

ENGINE COOLANT CONCENTRATION TEST

Refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .

Scheme 52

Scheme 53

1. Remove the fan control module connector.
2. Turn the ignition switch to the "ON" position, and measure the voltage between the harness-side connector terminals. Standard value: Battery positive voltage
3. Connect the fan control module connector, and disconnect the condenser fan motor connector.
4. Ensure that the A/C switch is off, and start the engine and run it at idle.
5. Measure the voltage between the fan control module-side connector terminals. Standard value: 1 V or less
6. Turn the A/C switch to the "ON" position. WARNING: Stay clear of the fan when the fan starts running.
7. Measure the voltage between the fan control module-side connector terminals while the fan is running. The voltage should repeat the values 1) and 2) below. Standard value: 1) 8.2+/-2.6 V 2) 2) Battery positive voltage+/-2.6 V
8. If the voltage does not repeatedly change as indicated, replace the fan control module.

FAN CONTROL RELAY CONTINUITY CHECK

FAN CONTROL RELAY CONTINUITY CHECK CHART

Scheme 54

Scheme 55

1. Remove the radiator fan motor connector.
2. Check to see that the fan motor of the radiator turns when applying battery power between the connector terminals of the radiator fan motor. Also check to see that there is no abnormal sound coming from the radiator fan motor at this time.
3. If the radiator fan motor is defective, replace it.

Scheme 56

Scheme 57

<< A >> RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Scheme 58

<< B >> TRANSMISSION FLUID COOLER HOSE CONNECTION

After disconnecting the hose, plug it to avoid entry of dust or foreign material.

Scheme 59

1. Insert each hose as far as the projection of the water inlet fitting, water outlet fitting or radiator.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

Scheme 60

Scheme 61

<< A >> RADIATOR LOWER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Scheme 62

>> A << THERMOSTAT INSTALLATION

Install the thermostat so that the jiggle valve is facing straight up. Be careful not to fold or scratch the rubber ring.

Scheme 63

Scheme 64

1. Insert each hose as far as the projection of the water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

Scheme 65

Scheme 66

1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: 82+/-1.5°C (180+/-3°F)
2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. Standard value: Full-opening temperature: 95°C (203°F) Amount of valve lift: 8.5 mm (0.33 inch) or more NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open.

Scheme 67

Scheme 68

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.
2. Apply a bead of the specified sealant. Specified sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent
3. With the sealant still wet (within 15 minutes after the sealant is applied), install the water pump. Do not apply the sealant in an area more than the required.

Scheme 69

Scheme 70

1. Fit the O-ring to the O-ring groove at the tip of the water inlet pipe.
2. Wet the O-ring or the inner part of the water pump assembling area with water or coolant, then insert the water inlet pipe.

>>B<< WATER PUMP INSTALLATION

WATER PUMP BOLT SPECIFICATION

Scheme 71

Scheme 72

<< A >> RADIATOR UPPER HOSE DISCONNECTION

After making mating marks on the radiator hose and hose clamp, disconnect the radiator hose.

Scheme 73

>>A<< WATER OUTLET FITTING/THERMOSTAT CASE ASSEMBLY INSTALLATION

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface. Specified Sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent
2. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case and water outlet fitting. Do not apply the sealant in an area more than the required.

Scheme 74

1. Insert each hose as far as the projection of the water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

>>C<< O-RING INSTALLATION

Insert the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant.

Scheme 75

Scheme 76

After making mating marks on the radiator hose and hose clamp, disconnect the radiator hose.

>>A<< O-RING INSTALLATION

Insert the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant.

Scheme 77

Scheme 78

Scheme 79

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.
2. Apply a bead of the sealant to the cylinder head mating surface of the thermostat case as shown. Specified Sealant: 3M™ AAD part No.8672, 3M™ AAD part No.8679/8678 or equivalent
3. Apply sealant to the thread of the thermostat case assembly bolts as shown. Specified Sealant: 3M™ AAD part No.4170 or equivalent
4. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case. Do not apply the sealant in an area more than the required.

Scheme 80

1. Insert each hose as far as the projection of the water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

Water Pipe and Hose Check

Check the water pipe and hose for cracks, damage and clogs. Replace them if necessary.

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

COOLANT

COOLANT SPECIFICATIONS

SEALANT

SEALANT SPECIFICATIONS

See also:
• 8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)
• MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK
• HARNESS CONNECTOR INSPECTION
• CONDENSER FAN MOTOR CHECK
• 1
• 4
• ENGINE COOLANT REPLACEMENT
• FAN CONTROL RELAY CONTINUITY CHECK