Cooling Mustrated Index . «. 10-2 Radiator Replacement Engine Coolant Refiling 10-5 and Bleeding .. Pec .. 10-6 Cap Testing .... Pressure Testing 10-8 Thermostat Replacement 10-9 Testing 10-9 Water Pump Illustrated Index . 10-10 Inspection ... 10-12 Replacement .. + 10-12Cooling Illustrated Index PSI system under a zaguron tngine fe hot. To avoid danger ing page 10-6 engine coolant, remove cap only when engine is cool Ceak ass page 10:8 Irapect soldered its ane CAUTION: When pouring engine coolant, be sure to -«=RADIATOR.GAP_ == seams fr leaks shut the relay Box id and not to et engine coolant spill cael Blow deat ran rena fon the electrical parts or the painted portion, If any Iinsects ete ate clogging engine coolent spills, rinse it off Immediately ‘adit. wash thom off with low pressure water NOTE: ‘© Check all cooling system hoses for damage, leaks oF deterioration and repiace if necessary © Check all hose clamps and retighten if necessary ‘© Use new O-rings when reassembiing Totel Cooling System Capacity: Inciuding reservoir 0.4 f (0.42 US gt, 0.35 Imp at) D16Z6, 01627 engine: M/T 4.5 € (1 19 US gal. 0.99 Imp gal) AIT 47 (1 24 US gal, 1.03 Imp ga) 6x 10mm RESERVOIR AO Nem (1.0 kgm. 7 tA Fan moron east wiz Nae Te tcp ton Thane Vawve Lowen Wi BSS ee Sa Are cootsn foes ad | APB PI NECTING THERMOSTAT HOUSING 10-2RADIATOR Fefling, sage 10-6 D16A9 engine: oak test page 10-8 MIT 4.51 (1.18 US gal, 0.99 Imp gab Inspect soldered Jonts and Blow din out from between Total Cooling System Capacity: Including reservoir 0.4 ¢ (0.42 US at, 0.25 Imp at) ‘ore fins with compressed air insects, etc, are clogeing radiator, wash them off with Lcopgahrala low pressure water Pressure tast.page 108 1 Gx10mm AON (1 O kgm. 7 ott) ber nial eee ‘SELF-LOCKING NUT lcamabnad : sanhoron,. LSU Ae CONNECTING } Bes ie a 10-3Cooling Illustrated Index (cont'd) PRTENME System is under high pressure when RADIATOR engine Is hot To avoid danger of releasing scalding Rating ose 10-5, ee ve wi ine is c gk test, paue engine coolant, remove cap only when engine is cool eee eee al seams for leaks CAUTION: When pouring engine coolant, be sure to Blow dirt out from between ‘shut the relay box lid and not to let engine coolant spill core fins with compressed! air fon the electrical parts or Winsects. etc. are cogging engine coolant spis, nse it off immediately piece memati aa RADIATOR CAP Pressure test. page 10-8 Note: 1 Check all cooling syatem hoses for dam deterioration and replace if necessary © Check all hse clamps ang reightenH necessary © Uso new Oringe when reeseombling Uppen RADIATOR Total Cooling System Capacity: Including 6x1.0mm TO Norm (1.0 ko-m. 7 Wf) ENGINE baal pLus COOLANT ‘SELF-LOCKING NUT RESERVOIR 45 Nem (0.45 ko-m. 3.3 fot \ FAN MOTOR ‘Test for operation ‘with 12 V'DC applied i Lowen RADIATOR HOSE connectins PIPE, . / ¢ oN é Zz FINS Se & \ [BYPASS HOSES COOLER HEATER Hoses: 10-4Radiator - Replacement 1. Drain the engine cootant 5. Remove the fan shroud assemblies and other pate 2. Remove the ubper and loner radiator hoses, and from radar. ATE cooler noses (AI) 3. Disconnect the fan motor connecter Install the radiator inthe reverse order of removal: Remove the tadiator upper brackets, then pull up the raditor Nore ‘© Sot the upper and lower cushions securely. ‘© Fill the radiator and bleed the eir 6x 1.0mm 10.Nem (1.9 kee UUpPER BRACKET 7 Ib-ft) ‘AND CUSHION RESERVOIR HOSE 4) ATF COOLER LOWER RADIATOR UPPER RADIATOR HOSES (A/7) Hose ~~ 6x10 mm TO N-m (1.0 kgm Tit 7 ‘COOLING FAN/SHROUD ‘ASSEMBLY FAN MOTOR CONNECTOR ATE COOLER PIPES (8/7) 10-5Radiator > Engine Coolant Refilling and Bleeding Removing the radiator cap while the engine is hot can cause the engine coolant to spray out, seriously scalding you. Always let the engine and .diator cool down before removing the radiator cap. CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not let engine coolant spi! on the electrical parts or the paint. If any engine coolant spills, rinse it off Immediately. 1. Start the engine. Slide the heater temperature con: trol lever to maximum heat and turn off the engine ‘Make sure the engine and radiator are coo! to the touch. 2. Remove the radiator cap. 3 Loosen the drain plug on the bottom of the radiator ‘and ramave the drain bolt on the engine block Let ‘the engine coolant drain out enaine Brain our Sonn en ee wasien Replace ~ G LYS D lA fe ~~ e RADIATOR, Remove the reservoir from its holder by pulling it straight up Drain the engine coolant, then put the reservoir back in its holder When the engine coolant stops draining, apply ti- ‘quid gasket to the drain bolt threads, then reinstall ‘the bolt with @ new washer Tighten it sacurely Tighten the radiator drain plug securely Mix the recommended antitreeze/engine coolant with an equal amount of water in clean container NOTE: ‘© Use only HONDA-RECOMMENDED antifreeze/ coolant © For best corrosion protection, the coolant con- centrations must be maintained yeer-round at 50% MINIMUM Engine coolant concentrations less than 50% may not provide sufficient tection against corrosion or freezing CAUTION: © Do not mix different brands of antifreeze! coolant © Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the recommended engine coolant, Engine Coolant Refill Capacity: Including reservoir 0.4 (0.42 US gt, 0.35 Imp qt! l ENGINE |____MiT at TYPE {(US gal, Imp galh | biez6, Dias | 36 10.98, 0.78) | 3.8 11.00. 0.84) | os 36 (0.95 079) — B16AZ 3.9 (7,03, 0.88) — 10-68. Pour engine coolent into the radiator up to the base ‘of the filer neck 9. Loosen the bleed bolt on top of the engine Tighten it again when engine coolant comes out in a steady stream with no bubbles, BLEED BOLT 10 Nom (1.0 kgm. 7 toto 10. Refill the radiator to the base of the filler neck. Put the cap on the radiator, and tighten it only to the first stop. Start the engine and let it run until it warms up (the radiator cooling fan comes on at least twice) 11. Turn off the engine. Check the level in the radiator add engine coolant if needed Install the radiator cap and tighten it fully 12 Fillthe reservoir to the MAX mark. Install the reser- voir cap, 10-7Radiator - Cap Testing 1. Remove the rediator cap, wot its seal with engine coolant, then install it on the pressure tester 2. Apply a pressure of 95-126 KPa (0 95—1.25 kglem?, 14-18 psi) 3. Check for a drop in pressure PRESSURE TESTER. RADIATOR cap ‘SMALL ADAPTOR ¥-301122.09 (Commercaly availabe) - Pressure Testing 1. Wait until the engine is coo}, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the fillar neck 2 Attach the pressure tester to the radiator and apply a pressure of 95~125 kPa (0.95-1 25 kgiem?, 14-18 psil| 3. Inspect for engine coolant leaks and a drop in pressure 4 Remove the tester and reinstall the radiator cep. NOTE: ‘© Check for engine oil in the engine coolant and/or engine coolant in the engine oll © Check for ATF in the engine coolant and/or ‘angine coolant in the ATF (A/T) PRESSURE TESTER ‘SMALL ADAPTOR ¥.901122.09 {Commercaly avaiable) 10-8Thermostat - Replacement NOTE: Use new gaskets and O-rings when reassem- bling ‘THERMOSTAT Install with pin up ‘THERMOSTAT HOUSING ‘THERMOSTAT MOUNTING RUBEER AS) Replace ES) pees ‘THERMOSTAT ‘covER 6x 1.0 mm 4ON-m (1 0 kom Tie GROUND TERMINAL ‘THERMOSWITCH A93 22-26 Nem (22-2.6 kgm. 4 16-19 bt - Testing Roplace thermostat if it is open at room temperature To test a closed thermostat: 1. Suspend the thermostat in a container of water as, shown. 2 Heat the water and check the temperature with 2 ‘thermometer. Check the temperature at which the thermostat first opens and at full it, ‘touch the CAUTION: Do not let the thermomet bottom of the hot container. 3. Meesure the lift height of the thermostat when it's full open STANDARD THERMOSTAT Starts opening: 78 = 2°C (172 = 4°F) Fully open: 90°C (194°F1 Litt height: 8.0 mm (0.31 in) ‘THERMOMETER THERMOSTAT erm 10-9Water Pump Mustrated Index NOTE: BLEED BOLT © Use new O-rings end new special bolts when 10% 1.25 mm teessembling 10.Nem (1.0 kgm. 7 Bott) ‘© Use liquid gasket, Part No. OY740~99986. Except B16A2 engine: ‘TEMPERATURE GAUGE ‘SENDER ~ 9 Nem (0.9 kgm, 7 Ibe) Apply liquid gasket to the treads ‘WATER OUTLET covER Foot ud gasket wa ‘Dimung sroce ‘THERMOSWITCH 493 22-26 Nem (22-26 kgm 16-19 tbe) ‘THERMOSTAT HOUSING ASSEMBLY CONNECTING PPE ALTERNATOR, ADJUST BRACKET. 6x10 mm re laaan 101.25 mm J2Nem (2 eae 45 Nem (4.5 kgm oot 33 bit 10-10B16A2 engine: WATER OUTLET coven Apply liquid gasket te mating surface BLEED BOLT 10x 125 mm 10 Nem (1.0 kgem. 7 Bott 6x 1.0 mm Nem (1.4 kgm Bib Replace TEMPERATURE GAUGE SENDER Nim (0 9 kgm. 7 I-A ECT SENSOR ‘Apply liquid gasket 16 Nem (1 8 kom, te the threads 13m WATER PUMP Inspection ‘THERMOSWITCH pags 10-12 33 2226 N 122-2 6 kgm, 16-19 tt) onNG O-RING 6x10 mm QO WV {) Replace 10 Nem {1.0 kgm 641mm cowNECTING Tee a o PIPE ee mi sme ee oans assem 10-11Water Pump -- Inspection 1. Remove the timing belt (D1826, 01627 engine: page 6-41, D1GA9 engine: page 6-68, B16A2 engine: page 6-103) 2. Check that the water pump pulley turns freely, 2 Check for signs of seal leakage NOTE: A small amount of “weeping” from the bleed hole is normal. Except 816A2 engine: BLEED HOLE BLEED HOLE B16A2 engine: LEED HOLE -~ Replacement EeRerE eee eer 1. Remove the timing belt (D1626, 01627 engine: page 6-41, D16A9 engine: page 6-68, B16A2 ‘engine: page 6-103) 2 Remove the water pump by removing five bolts. 3. Install the water pump in the reverse order of removal RING Replace WATER PUMP. 6x10 mm 12Nem (1.2 kien. 9 tote) wy 45 Nem (4 5 kgm ALTERNATOR, 33 ef) ‘ADJUST BRACKET 10-12