CHAPTER 2 COOLING SYSTEM

Chapter 2 COOLING SYSTEM

1. Specifications

Item Specifications
Cooling method Water-cooled, forced circulation

Cooling Radiator Corrugate type, pressurized

system Water pump Centrifugal type
Thermostat Wax pellet type

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CHAPTER 2 COOLING SYSTEM
2. Structure

2
8
3

1)

4
2)

3) 5
6
7

502537
1. Fan (coupled directly to engine crankshaft) 7. Upper hose
2. Radiator 8. Hose arrangement
3. Shroud 1) S4Q2 engine
4. Lower hose 2) Gasoline engine
5. Reserve tank (gasoline engine) 3) S4S engine
6. Reserve tank (S4Q2 and S4S)

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 CHAPTER 2 COOLING SYSTEM
3. Fan Belt, Removing
3.1 Preparation

Remove radiator cover.

3.2 Removal Sequence

1 2
502538
1. Tension assembly (pulley lock bolt) 3. Fan
2. Fan belt

3.3 Suggestions for Removal

(1) Loosen pulley lock bolt by rotating it 3 to 4 turns. If bolt

is not loosened adequately, the pulley will not move. 1
Note: Do not remove pulley lock bolt, just loosen it. 1)
If the alternator will not move, rotate the nut about 1
turn. Do not forcibly rotate, as the bracket may break.
2
(2) Move tension pulley fully toward the fan, then remove
the belt. 3

503077
1. Lock bolt 1) Fan side
2. Tension pulley
3. Nut

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CHAPTER 2 COOLING SYSTEM
4. Fan Belt, Installing
For installation, follow the removal sequence in reverse.
4.1 Suggestions for Installation

(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it generates
abnormal noises.
(2) Make sure that tension pulley moves when pushing the
belt by hand.
(3) Tighten lock bolt and locknut firmly.
5. Cooling System, Inspecting and Adjusting
5.1 Fan Belt Inspection

(1) Check the belt for contamination by oil, grease, or dust.

Replace the belt as required. When there is slight
contamination, clean the belt with a rag or paper towel.
Do not wash with gasoline, oil, or any other solvent.
(2) During engine overhaul or belt tension adjustment,
carefully check condition of belt. If it has any damage,
replace belt with new one.
5.2 Fan Belt Tension Adjustment

R WARNING
Always turn the engine OFF when adjusting fan belt tension.

Adjust the belt deflection to the specified range below,

while applying force of 98 N (10.0 kgf) [22.03 lbf] 1
perpendicularly to the belt midway between fan pulley and
tension pulley.
2

503078
1. Fan pulley 2. Tension pulley

Standard
Item
Gasoline models Diesel models
Deflection 11 to 13 mm (0.43 to 0.51 in.) 10 to 12 mm (0.39 to 0.47 in.)

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 CHAPTER 2 COOLING SYSTEM
5.3 Hoses, Connecting
When connecting the hoses to the radiator, fit their ends
fully on the fittings and secure them with clamps. Make sure 1
that each hose is correctly connected over the flare of the
fitting.

502541
1. Hose

5.4 Cooling Water

Fill the radiator with coolant containing antifreeze, and start

the engine. Check for abnormal noise during engine warm-
up operation. For K-type gasoline engines, loosen air vent
plug on the top of water pump.
Make sure that the coolant in the radiator is at its highest
level, all the way up to the neck. Also make sure the coolant
reserve tank is full of coolant to the specified level.
Coolant quantity

Item K15 K21, K25 S4Q2 S4S

0.65 L 0.65 L 0.65 L 0.65 L
Reserve tank (FULL level)
(0.1717 US gal.) (0.1717 US gal.) (0.1717 US gal.) (0.1717 US gal.)
Total quantity of coolant (including 6.8 L 6.8 L 7.4 L 8.7 L
coolant in hoses) (1.797 US gal.) (1.797 US gal.) (1.955 US gal.) (2.299 US gal.)

5.5 Radiator Cap

Item Specifications
Opening pressure 88 ± 14.7 kPa (0.90 ± 0.15 kgf/cm2) [12.765 ± 2.132 psi]
Vacuum valve 0 to 4.9 kPa (0 to 0.05 kgf/cm2) [0 to 0.711 psi]

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