COOLING SYSTEM (J08E)
7—1
COOLING SYSTEM (J08E)
7-001
COOLING SYSTEM.....................7-2
DIAGRAM..........................7-2
COOLANT PUMP.......................7-3
COMPONENT LOCATOR................7-3
SPECIAL TOOL.....................7-4
OVERHAUL.........................7-5
INSPECTION AND REPAIR............7-8
THERMOSTAT.........................7-9
COMPONENT LOCATOR................7-9
OVERHAUL........................7-10
RADIATOR..........................7-12
COMPONENT LOCATOR...............7-12
SPECIAL TOOL....................7-13
OVERHAUL........................7-13
INSPECTION AND REPAIR...........7-17
INTERCOOLER.......................7-18
COMPONENT LOCATOR...............7-18
OVERHAUL........................7-19
INSPECTION AND REPAIR...........7-20
COOLING FAN.......................7-21
COMPONENT LOCATOR...............7-21
INSPECTION AND REPAIR...........7-22
COOLANT TEMPERATURE SENSOR........7-23
COMPONENT LOCATOR...............7-23
REPLACEMENT.....................7-24
7—2
COOLING SYSTEM (J08E)
COOLING SYSTEM
DIAGRAM
EN01F01103060J01001001
SHTS011030600001
1	Reservoir tank	8	Air compressor
2	Radiator cap	9	Turbocharger
3	Radiator	10	Cylinder head
4	Coolant temperature gauge	11	Cylinder block
5	Thermostat case	12	Oil cooler
6	Thermostat	13	Drain plug
7	Coolant pump		
COOLING SYSTEM (J08E)
7-3
COOLANT PUMP
COMPONENT LOCATOR
EN01F01103060D01002001
SHTS011030600002
1	Fan pulley	7	Case
2	O-ring*	8	Mechanical seal *
3	Coolant pump assembly	9	Vane
4	Pulley center	10	Clip (If so equipped)
5	Retainer ring*	11	Cap (If so equipped)
6	Coolant pump shaft		
*: Nonreusable part
Tightening torque
Unit: N m {kgf cm, Ibfft}
A 28.5 {291, 21}	
7-4
COOLING SYSTEM (J08E)
SPECIAL TOOL
EN01F01103060K01002001
Prior to starting an engine overhaul, it is necessary to have these special tools.
Illustration	Part No.	Name	Remarks
	S0942-01810	PULLER	For coolant pump pulley center
	S0942-01820	PULLER	For coolant pump vane
	S0948-22060	PRESS	For coolant pump seal
COOLING SYSTEM (J08E)
7-5
OVERHAUL
EN01F01103060H02002001
IMPORTANT POINT - DISASSEMBLY
SHTS011030600009
1.	DISASSEMBLE THE COOLANT PUMP.
(1)	Remove the vane from the shaft using the special tool.
SST: S0942-01820
Puller
(2)	Remove the pulley center from the shaft using the special
tool.
SST: S0942-01810
Puller
(3)	Remove the retainer ring from the pump case using snap ring
pliers.
(4)	Push the shaft from the vane side using a hydraulic press,
and remove the coolant shaft from the pump case.
NOTICE
Before pressing, recheck that the retainer ring is removed com-
pletely.
7-6
COOLING SYSTEM (J08E)
SHTS011030600011
(5)	Remove the coolant seal from the pump case using a ham-
mer and brass bar.
Д WARNING
Impact due to punching may cause metal chips to fly up. Be sure
to wear protective goggles.
NOTICE
Replace the removed coolant seal with a new one. Never reuse it.
IMPORTANT POINT - ASSEMBLY
1.	ASSEMBLE THE COOLANT PUMP.
(1)	Install the coolant shaft onto the pump case using a hydraulic
press.
Assembly standard (A): 4.9-5.1 mm {0.193-0.2007 in.}
NOTICE
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.
(2)	Install the retainer ring onto the pump case using snap ring
pliers.
(3)	Install the pulley center onto the shaft using a hydraulic
press.
Standard: 149.7-150.5 mm {5.894-5.925 in.} from the pulley
center mounting surface to the pump case end
surface
SHTS011030600013
COOLING SYSTEM (J08E)
7-7
SHTS011030600014
SHTS011030600015
SHTS011030600016
SHTS011030600017
(4)	Install the new coolant seal.
a.	Apply liquid gasket (ThreeBond #1184 or equivalent) to the
seal outer circumference and case bore.
b.	Install the seal to the case and shaft using a press.
SST: S0948-22060
Press
NOTICE
Replace the coolant seal with new one.
(5)	Apply liquid gasket (ThreeBond #1184 or equivalent) ass-
hown in the figure to the entire shaft circumference.
(6)	Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.7-1.3 mm {0.0275-0.0511 in.}
NOTICE
Press until the vane end face comes into contact with the shaft
end surface.
(7)	After assembly, turn the shaft by hand and make sure that
there is no noise, catching or rough movement in the shaft
direction and that it rotates smoothly.
7—8
COOLING SYSTEM (J08E)
INSPECTION AND REPAIR
EN01F01103060H03002001
Unit: mm {in.}
Inspection item	Standard	Limit	Remedy	Inspection procedure
Wear, damage and corrosion	—	—	Replace parts.	Visual check
Tightness of shaft and vane	0.015-0.048 {0.0006-0.0018}	—	Replace shaft and/or vane.	Measure
Tightness of shaft and pulley center	0.029-0.063 {0.0012-0.0024}	—	Replace shaft and/or pulley center.	Measure
NOTICE
•	Tightness = Outside diameter - Inside diameter
•	Prevent a reassembly more than three times even if it is within
the standard value.
COOLING SYSTEM (J08E)
7—9
THERMOSTAT
COMPONENT LOCATOR
EN01F01103060D01003001
SHTS011030600021
1	Thermostat case assembly	4	Thermostat case
2	Thermostat case cover	5	Thermostat
3	O-ring*	6	Gasket
*: Nonreusable part
Tightening torque
Unit: N m {kgf cm, Ibf ft}
A 28.5 {291, 21}	
7-10
COOLING SYSTEM (J08E)
OVERHAUL
EN01F01103060H02003001
IMPORTANT POINT - INSPECTION AND REPAIR
SHTS011030600023
1. INSPECT THE THERMOSTAT FUNCTION.
(1) Place the thermostat in hot water and check the valve open-
ing temperature and the valve lift.
Thermostat valve opening temperature:
Thermostat valve opening temperature. (T1)	Service standard
82 °C {180 °F}	80-84 °C {176-183 °F}
NOTICE
Check that the thermostat valve opening temperature (T-|) is
engraved on the thermostat seat.
Thermostat valve lift:
Thermostat valve opening temp. (T-j)	Measuring temp. (T2)	Valve lift (L2-L-|)
82 °C {180 °F}	95 °C {203 °F}	13 mm {0.512 in.} or more
(2) Immerse the opened thermostat in water at normal tempera-
ture. If it completely closes within 5 minutes, it is satisfactory.
If it remains slightly open, it is defective and must be
replaced.
COOLING SYSTEM (J08E)
7-11
IMPORTANT POINT - ASSEMBLY
SHTS011030600025
1. ASSEMBLE THE THERMOSTAT CASE.
NOTICE
•	Remove water or dirt adhering to the thermostat case.
•	Be sure to replace the gasket if it is corroded, damaged or flat-
tened.
•	Before installing the hose, apply liquid gasket to the hose
installation part of the thermostat case cover.
•	To prevent clogging of the radiator, do not use a large amount of
liquid gasket.
•	Be sure that the jiggle valve faces upward when installing it.
IMPORTANT POINT - MOUNTING
1.	INSTALL THE THERMOSTAT CASE ASSEMBLY.
(1)	Apply liquid gasket to the thermostat case.
(2)	Install the О-ring into the groove of the coolant pump.
(3)	Temporarily tighten the bolts "1" and bolts "2" in that order,
and securely contact the fitting surface.
(4)	Tighten the bolts in numeral order.
SHTS011030600026
7-12
COOLING SYSTEM (J08E)
RADIATOR
COMPONENT LOCATOR
EN01F01103060D01004001
SHTS011030600027
1	Radiator cap	8	Distance piece
2	Upper tank	9	Radiator fitting cushion
3	Radiator core	10	Right support
4	Left support	11	Coolant level switch
5	Drain plug	12	Hose
6	Lower tank	13	Baffle plate
7	O-ring *		
*: Nonreusable part	
Tightening torque	Unit: N m {kgfcm, Ibf ft}
A 6-7 {62-71,4.5-5.1}	В 14-20 {143-203, 11-14}
COOLING SYSTEM (J08E)
7-13
SPECIAL TOOL
Prior to starting a radiator overhaul, it is necessary to have these special tools.
EN01F01103060K01004001
Illustration		Part No.	Name	Remarks
		S0976-01030	RADIATOR TOOL	For uncaulking
				
I—=	QI	S0976-01040	RADIATOR TOOL	For caulking
				(Used with S0976-01030)
SHTS011030600030
OVERHAUL
EN01F01103060H02004001
IMPORTANT POINT - DISMOUNTING
1.	DRAINING THE COOLANT
(1)	Drain the coolant from the drain cock of the radiator and the
drain plug of the oil cooler.
A warning
Drain the coolant after the coolant temperature is lowered enough
to prevent burning.
NOTICE
Dispose of coolant in accordance with the specified procedures
(industrial waste disposal) or other environment-friendly prac-
tices.
HINT
•	With the radiator cap removed, coolant can be drained faster.
•	Coolant can be drained without splashing by connecting the
proper hose to the oil cooler drain pipe.
2.	DISMOUNT THE RADIATOR.
Awarning
•	Never remove the radiator cap when the coolant temperature is
high.
•	To avoid the danger of burns and scalds, do not drain the cool-
ant while the engine and radiator are still hot.
NOTICE
When dismounting and mounting the radiator, do not damage the
radiator core.
7-14
COOLING SYSTEM (J08E)
IMPORTANT POINT - DISASSEMBLY
NOTICE
Recaulking should be limited to twice.
1.	DISASSEMBLE THE UPPER TANK, LOWER TANK AND RADI-
ATOR CORE.
(1)	Remove the left support and right support.
SHTS011030600032
(2)	Grip the handle until it hits to the stopper bolt, then adjust the
dimensions A with stopper bolt.
Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.}
SST: S0976-01030
Radiator tool
NOTICE
Be sure to adjust the dimension to prevent damage of the crow.
TOOL FOR STRIPPING OFF
SHTS011030600033
(3)	Using a special tool, lift the staked part.
NOTICE
Do not lift up tangs more than 90°.
SHTS011030600034
(4)	Remove the upper tank and lower tank from the radiator core
by tapping lightly with plastic hammer.
NOTICE
Do not remove the tank by forcing or prying.
COOLING SYSTEM (J08E)
7-15
IMPORTANT POINT - ASSEMBLY
S0976-01040
S0976-01030
1. ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIA-
TOR CORE.
(1)	Exchange the crow of the radiator tool (S0976-01030) for the
radiator tool (S0976-01040) as shown in the figure.
SST: S0976-01030
Radiator tool
S0976-01040
Radiator tool
SHTS011030600035
STOPPER BOLT
(2)	Grip the handle of the radiator tool until it hits to the stopper
bolt, then adjust the dimensions В with stopper bolt.
Dimension B: 10 mm {0.394 in.}
SHTS011030600036
(3)	Install the new О-ring into the groove of the radiator core
(upper and lower) in such away that it will not be twisted.
NOTICE
Be sure to clean the fitting portion before installing. When clean-
ing, lightly rub the inside portion of the groove with the emery
paper.
(4)	Install the upper tank and lower tank into the groove of the
radiator core.
SHTS011030600038
(5)	Flap the tangs to obtain a tight contact with the upper tank
and lower tank.
7-16
COOLING SYSTEM (J08E)
SHTS011030600041
(6)	Press the radiator tool (caulking tool) against the side por-
tion. Temporarily caulk the tangs several times, then proceed
to the final caulking by gripping the handle until it hits the
stopper bolt.
NOTICE
For the positions where the radiator tool is not usable, perform the
caulking with pliers.
NOTICE
Perform the caulking according to the sequence as shown in the
figure.
(7)	Check the dimension C.
Assembly standard: 8.12-8.7 mm {0.3197-0.3425 in.}
If the dimension is out of the standard value, adjust the stop-
per bolt of the handle once again and perform the caulking
again.
IMPORTANT POINT - MOUNTING
1.	ADDING THE COOLANT
(1)	Add the coolant slowly from the cap of the reserve tank.
Coolant level: 21.5 L {4.73 Imp.gal, 5.68 U.S.gal.}
Д WARNING
•	Improper or careless removal of the radiator cap may cause
burns from spewing hot coolant or vapor. Remove the cap after
the coolant temperature gauge reads below the specified tem-
perature.
•	If the cap is not tightened securely, it may cause overheat and
furthermore, high-temperature coolant may spray out at the
time of overheat.
A CAUTION
Entry of air causes overheat and coolant leakage from the coolant
pump.
COOLING SYSTEM (J08E)
7-17
NOTICE
•	A sudden adding prevents air in the cooling pipe system from
bleeding smoothly, resulting in a prolonged adding.
•	If air blows back, once stop adding coolant and wait for a while
before resuming.
•	To add the tap water, do not fully open the tap water cock but
keep it half-open.
•	Check the engine oil and fuel system and cooling system for
leakage and abnormal noise.
INSPECTION AND REPAIR
EN01F01103060H 03004001
Unit: kPa {kgf/cm2, lbf/in.2}
Inspection item		Standard	Limit	Remedy	Inspection procedure
Air leakage (When the air pressure of 177 {1.8, 25.67} is applied.)		—	—	Replace radiator.	Visual check
Clogging of the Fines		—	—	Clean.	
Radiator cap valve opening pressure	Mark 0.5	39-59 {0.4-0.6, 5.66- 8.55}	—	Replace.	Measure I 'SnlF-
NOTICE
•	The coolant filler cap valve opening pressure is indicated on the
cap and it should be confirmed. If the cap pressure is incorrect,
there is a risk of abnormally high pressure being generated in
the cooling system, which may cause the hose to drop off or
burst and may result in the damage of the engine.
•	When carrying out high pressure washing to remove fin clog-
ging, do not apply excessive pressure to the fins which may
cause deformation and consequent performance deterioration.
7-18
COOLING SYSTEM (J08E)
COMPONENT LOCATOR
INTERCOOLER
EN01F01103060D01005001
SHTS011030600044
2 Intercooler
1 Radiator
Tightening torque
Unit: N m {kgf cm, Ibf ft}
A 14-20 {143-203, 11-14}
COOLING SYSTEM (J08E)
7-19
OVERHAUL
REMOVING THE INTERCOOLER
EN01F01103060H02005001
SHTS011030600045
SHTS011030600046
1. REMOVING THE INTERCOOLER
(1) Remove the radiator and intercooler as a unit.
(2) Remove the 4 bolts to remove the intercooler from the radia-
tor.
NOTICE
•	Make sure not to damage the fins of the radiator core and inter-
cooler core.
•	To prevent water leakage, care must be exercised not to damage
hoses and other parts when installing plug.
INSTALLING THE INTERCOOLER
1. INSTALLING THE INTERCOOLER
(1) Install the intercooler to the radiator with the 4 bolts.
Tightening Torque:
14-20 N-m {143-203 kgf-cm, 11-14 Ibf-ft}
NOTICE
Make sure not to damage the fins of the radiator core and inter-
cooler core.
(2) Install the radiator and intercooler as a unit.
7-20
COOLING SYSTEM (J08E)
INSPECTION AND REPAIR
EN01F01103060H03005001
Unit: kPa {kgf/cm2, lbf/in.2}
Inspection item	Standard	Limit	Remedy	Inspection procedure
Intercooler •	Air leakage test (when the air pressure of 177{1.8, 25.67} is applied.) •	Clogging of the fins	0 mL	—	Replace the intercooler.	V® I
	—	—	Clean.	
NOTICE
When carrying out high pressure washing to remove fin clogging,
do not apply excessive pressure to the fins which may cause
deformation and consequent performance deterioration.
COOLING SYSTEM (J08E)
7-21
COOLING FAN
COMPONENT LOCATOR
EN01F01103060D01006001
1 Cooling fan	2 Fan clutch
NOTICE
•	Shock to the fan clutch and fan.
During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting
damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become dam-
aged or deformed if force is applied to it.
•	Replace the fan.
Do not replace the fan unless it is faulty. When replacing the fan, replace with the same type. If the fan is
replaced with one of a larger capacity because of overheating or, conversely is replaced with one of a smaller
capacity due to overcooling, the performance may in fact be reduced and durability may be jeopardized.
•	Other items
Check the bimetal to see if there is any mud or dust on it. If the bimetal is covered with mud or dust, the fan per-
formance will be erratic, and may result in overheating or overcooling. In such case, carefully remove mud and
dust adhering to the surface of the bimetal, using a wire brush, or the like.
Take particular care not to apply excessive force.
Do not paint the fan or fan clutch. Do not place any paint or other reagents which are likely to dissolve plastic in
contact with the fan.
7—22
COOLING SYSTEM (J08E)
INSPECTION AND REPAIR
EN01F01103060H03006001
Inspection item	Standard	Limit	Remedy	Inspection procedure
Cooling fan and fan clutch deformation and damage	—	—	Replace if necessary.	Visual check
COOLING SYSTEM (J08E)
7-23
COOLANT TEMPERATURE SENSOR
COMPONENT LOCATOR
EN01F01103060D01010001
1 Coolant temperature sensor	2 Gasket *
*: Nonreusable part
Tightening torque
Unit: N m {kgf cm, Ibf ft}
A 26.95-31.85 {275-324, 20-23}	
7-24
COOLING SYSTEM (J08E)
REPLACEMENT
EN01F01103060H01010001
REMOVING THE COOLANT TEMPERATURE SEN-
SOR
SHTS011030600052
COOLANT TEMPERATURE SENSOR
SHTS011030600053
1. REMOVING THE COOLANT TEMPERATURE SENSOR
(1) Disconnect the connector from the coolant temperature sen-
sor.
HINT
Prepare a reservoir and clean cloths to collect dripping coolant
when removing the coolant temperature sensor.
(2) Remove the coolant temperature sensor and gasket from the
coolant outlet pipe.
SINGLE UNIT INSPECTION
1. INSPECTING THE RESISTANCE
(1) Warm the coolant temperature sensor using water or a long
life coolant (undiluted).
(2) Using the circuit tester a measure the resistance between the
terminals. If the value exceeds the standard value, replace it.
Between A terminal and C terminal
Temperature (°C {°F})	Standard value (kQ)
-20 {-4}	13.84-16.33
20 {68}	2.32-2.59
80 {176}	0.310-0.326
110{230}	0.1399-0.1435
Between В terminal and coolant temperature sensor
Temperature (°C {°F})	Standard value (Q)
75 {167}	79-92
100 {212}	35.5-42.5
COOLING SYSTEM (J08E)
7-25
INSTALLING THE COOLANT TEMPERATURE SEN-
SOR
SHTS011030600054
SHTS011030600055
1. INSTALLING THE COOLANT TEMPERATURE SENSOR
(1) Replace with a new gasket and install the coolant tempera-
ture sensor to the coolant outlet pipe.
Tightening Torque:
26.95-31.85 N-m {275-324 kgf cm, 20-23 Ibf-ft}
(2) Connect the connector to the coolant temperature sensor.
2. ADDING THE COOLANT
(1) Inspect the coolant level and if insufficient, add the coolant.