Cooling System

Repair Procedures

Inspection

Radiator Hoses

1. Inspect the radiator hoses for the following:

   1. Improper installation

   2. Leaks

   3. Cracks

   4. Damage

   5. Loose connections

   6. Chafing

   7. Deterioration

Coolant Level

1. 1

   Check the coolant level in the coolant reservoir. Make sure it is between the "F" mark and the "L" mark.

2. 2

   If the coolant level in the coolant reservoir is at or below the "L" mark, add coolant so that it is between the "L" and "F" marks, then inspect the cooling system for leaks.

Coolant Quality

1. 1

   Remove the radiator cap.

2. 2

   Check for excessive rust or scale deposits around the radiator cap assembly and the radiator filler neck. Also, make sure the coolant is free of oil.

   If there is excessive contamination, clean the coolant passages and replace the coolant.

3. 3

   Install the radiator cap.

Engine Coolant Filling and Bleeding

[R 2.2 / Theta-II 2.0 T-GDI]

1. 1

   Make sure the engine and radiator are cold to the touch.

2. 2

   Remove the radiator cap (A).

   [R 2.2]

   

   [Theta-II 2.0 T-GDI]

   

3. 3

   Remove the engine compartment under cover (front).

   (Refer to Engine Mechanical System - "Engine Room Cover")

4. 4

   Loosen the drain plug (A) and drain the engine coolant.

   

5. 5

   Tighten the radiator drain plug securely after draining the engine coolant.

6. 6

   After draining the engine coolant, clean the reservoir tank.

7. 7

   Fill the radiator with water through the radiator cap and tighten the cap.

8. 8

   Start the engine and warm it up to normal operating temperature. Wait for the cooling fans to turn on several times. Rev the engine to help purge trapped air. Stop the engine.

9. 9

   Wait until the engine has cooled down.

10. 10

    Repeat steps 1 through 9 until the drained water is clean.

11. 11

    Fill the mixed coolant and water (55 - 60%) (except North America, Europe and China: 45-50%) slowly through the radiator cap. Push the upper/lower radiator hoses to help release air.

12. 12

    Start the engine and allow the coolant to circulate.

    When the cooling fan is operating and the coolant is circulating, add coolant through the radiator cap.

13. 13

    Repeat step 12 until the cooling fan has come on 3 to 5 times and sufficient air has been bled from the cooling system.

14. 14

    Install the radiator cap and fill the coolant reservoir to the "MAX" (or "F") line.

15. 15

    Run the vehicle at idle until the cooling fan has cycled 2–3 times.

16. 16

    Stop the engine and wait for the coolant to cool down.

17. 17

    Repeat steps 11 through 16 until the coolant level stops dropping, bleeding air from the cooling system.

    Coolant Capacity

    [R 2.2]

    Approx. 11 L (2.90 US gal, 11.6 US qt, 9.67 Imp. qt)

    [Theta-II 2.0 T-GDI]

    Approx. 8.8 L (2.32 US gal, 9.30 US qt, 7.74 Imp qt)

[Lambda-II 3.3 T-GDI]

1. 1

   Make sure the engine and radiator are cold to the touch.

2. 2

   Remove the radiator cap (A).

   

3. 3

   Remove the engine compartment under cover (front).

   (Refer to Engine Mechanical System - "Engine Room Cover")

4. 4

   Loosen the drain plug (A) and drain the coolant.

   

5. 5

   Tighten the radiator drain plug securely.

6. 6

   Remove the reservoir tank.

   (Refer to Engine Mechanical System - Reservoir)

7. 7

   Drain the coolant from the coolant reservoir and clean the coolant reservoir.

8. 8

   Install the expansion tank.

   (Refer to Engine Mechanical System - Reservoir)

9. 9

   Detach the wiring protector (A).

   

10. 10

    Remove the foam (A).

    

11. 11

    Disconnect the coolant vent hose (A).

    

12. 12

    Slowly fill with a mixture of coolant and water (55 - 60 % / or 45 - 50 % in North America, Europe and China) through the radiator cap.

    Squeeze the upper/lower radiator hoses to easily bleed the air.

    Coolant capacity:

    approx. 11.6 L (3.06 US gal, 12.26 US qt, 10.20 Imp. qt)

13. 13

    After the coolant has drained through the disconnected vent hose, reconnect the vent hose and secure it firmly to the nipple.

14. 14

    Connect KDS.

15. 15

    Start the engine.

16. 16

    Turn off the A/C and heater, then run them for 10 minutes to raise the engine coolant temperature.

17. 17

    Perform the "Engine Coolant Filling Mode".

    

18. 18

    After confirming that the vehicle condition meets the inspection conditions, click the "OK" button.

    

19. 19

    Check the conditions for entering the engine coolant filling mode, then click "Read" to check the current coolant temperature.

    

20. 20

    Check the current coolant temperature and click the "OK" button.

    

21. 21

    If the coolant temperature is above 75 °C, click "OK" to perform the engine coolant filling mode.

    

22. 22

    The engine coolant filling mode is maintained until the coolant temperature reaches 75 °C.

    

23. 23

    When the engine coolant filling mode is completed, click the "OK" button.

    

24. 24

    Disconnect KDS.

25. 25

    Maintain engine speed between 2000 and 3000 rpm for approximately 3 minutes to improve coolant circulation.

26. 26

    Run the engine at idle for 3 minutes to check whether the cooling fan operates.

27. 27

    Wait 15 minutes after the engine is turned off.

28. 28

    Install the radiator cap (A).

    

29. 29

    Check the coolant level and fill the reservoir with coolant up to the "F" line.

30. 30

    Install the foam (A).

    

31. 31

    Install the wiring protector (A).

    Tightening torque:

    6.9–9.8 N·m (0.7–1.0 kgf·m, 5.1–7.2 ft-lbf, 60.8–86.8 in-lbf)

    

32. 32

    Install the front engine room lower cover.

    (Refer to Engine Mechanical System - "Engine Room Cover")