Inspection

Radiator Cap Valve 1. Remove foreign material(such as water residue) from between the radiator cap valve and the valve set. 2. Attach radiator cap to a radiator cap tester(commercially available). Apply pressure gradually to 15psi(103kPa). 3. Wait about 10seconds. Check that the indicated pressure has not decreased. Replace the radiator cap if the pressure has leaked off. Cooling system 1. Pressure teat the cooling system to 15psi(103kPa) using the radiator system tester. If the system fail to hold 15psi(103kPa), check the system for leakage while under pressure. It is likely to be a hose or hose connection. Overheating • Never remove the radiator cap when the engine is hot. Remove the radiator cap from a hot engine could result in a serious burn. Wrap a thick cloth around the cap when removing it. • When removing either the radiator cap or the tester, loosen it slowly until the pressure is released. Then remove it. 1. Make sure engine is cold before inspection. 2. Inspect coolant level at the coolant reservoir tank and radiator filler neck. Add coolant as required. 3. Inspect for rust or scales in either the reservoir tank or filler neck. If rust or any kind of contamination is detectedat either place, flush system thoroughly and new coolant as required. 4. Inspect for oil in either the reservoir tank or radiator filler neck. If oil is found in either place, it is likely there is a leaking head gasket. Refer to Engine for head gasket removal and installation. 5. Inspect for coolant leakage at the radiator. If the radiator leaks, repair or replace radiator. Refer to “Radiator” in this section. Head Gasket 1. Inspect the engine oil dipstick for the odor of antifreeze. If the dipstick small of antifreeze, the most probable cause is a leaking head gasket. Never remove the radiator cap when the engine is hot. Removing the radiator cap from a hot engine could result in a serious burn. Wrap a thick cloth around the cap when removing it. 2. Start the engine. Inspect exhaust and coolant to determine if coolant is entering the combustion chamber. Remove radiator cap. If engine exhaust is white smoke or if there are bubbles in the coolant as viewed through the radiator the radiator neck, coolant is entering the combustion chamber. Install radiator cap. Shut the engine off. Refer to Engine for headgasket removal and replacement. Front Housing Gasket 1. Inspect for coolant around the front housing. The appearance of coolant in the area of the front housing would indicate the gasket surrounding the coolant passage leaks to the atmosphere. The front housing gasket must be replaced. 2. Inspect for the presence of oil in the coolant. The presence of oil in the coolant indicates there is an internal leak between the two passages. The front housing gasket must be replaced. For removal of the front gasket, refer to Engine. Transmission Oil Cooler Inspect the automatic transmission fluid dipstick to see if there is gum or varnish on it. If there is gum or varnish onthe dipstick, repair or replace the transmission oil cooler in the radiator. If coolant appears in the transmission fluid, the transmission must be completely disassembled, cleaned and repaired as required. Refer to “Radiator” in this section. Coolant Temperature sensor Refer to Emission Control System for inspection and removal of the coolant temperature sensor. Removal Annual Cooling System flush Waste coolant is harmful to the environment. It must be disposed of in accordance with local regulations. This engine does not have an engine block drain. 1. Remove the thermostat housing from the engine block. 2. Remove the thermostat and retain. 3. Install the thermostat housing. Tighten the two thermostat nuts to 16lb·ft(22N·m) 4. Remove the radiator cap. 5. Remove the under cover. 6. Open the drain cock and drain the coolant into a suitable container. Discard in an environmentally-safe manner. The container will be emptied several times. 7. Close drain cock. 8. Remove the reservoir tank and flush repeatedly with plain water. 9. Fill the cooling system completely with plain water. 10. Start the engine. 11. Add water as required. 12. Open the drain cock. 13. Add water to keep the radiator full. 14. Continue this procedure until the drained water is clean and clear. 15. Drain water from the radiator and block. 16. Close the drain. 17. Flush the thermostat with plain water. Installation 1. Install the thermostat. 2. Install the thermostat cover. Tighten the two mounting bolts to 16lb·ft(22N·m) 3. Install the reservoir tank. 4. Fill cooling system with coolant mixed in the desired proportion. 5. Install the radiator cap. 6. Shut engine off.

---