Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Procedure A
- Inspection Start
Do you have CONSULT-II?
Yes or No
- Yes: Go to 2.
- No: Go to 3.
- Check Cooling Fan Operation
With CONSULT-II
- Start engine and let it idle.
- Select COOLING FAN in ACTIVE TEST mode with CONSULT-II.
- Make sure that cooling fans-1 and -2 operate at each speed (LOW/MID/HI).
OK or NG
- OK: Go to 4.
- NG: Check cooling fan control circuit. Go to PROCEDURE B .
- Check Cooling Fan Operation
Without CONSULT-II
- Perform IPDM E/R auto active test and check cooling fan motors operation, Refer to Auto Active Test .
- Make sure that cooling fans-1 and -2 operate at each speed (Low/Middle/High).
OK or NG
- OK: Go to 4.
- NG: Check cooling fan control circuit. Go to PROCEDURE B .
- Check Cooling System For Leak
Apply pressure to the cooling system with a tester, and check if the pressure drops.
- Testing pressure: 157 kPa (1.6 kg/cm2 , 23 psi)
CAUTION: Higher than the specified pressure may cause radiator damage. Pressure should not drop.OK or NG
- OK: Go to 5.
- NG: Check the following for leak. Refer to
LEVEL CHECK
.
- Hose
- Radiator
- Water pump
- Check Radiator Cap
Apply pressure to cap with a tester.
- Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2 , 9 - 14 psi)
OK or NG
- OK: Go to 6.
- NG: Replace radiator cap.
- Check Thermostat
- Check valve seating condition at normal room temperatures.
It should seat tightly .
- Check valve opening temperature and valve lift.
- Valve opening temperature: 76.5° C (170° F) [standard]
- Valve lift: More than 8.6 mm/90° C (0.339 in/194° F)
- Check if valve is closed at 5° C (9° F) below valve opening temperature.
For details, refer to WATER INLET AND THERMOSTAT ASSEMBLY .
OK or NG
- OK: Go to 7.
- NG: Replace thermostat
- Check valve seating condition at normal room temperatures.
- Check Engine Coolant Temperature Sensor
Refer to COMPONENT INSPECTION .
OK or NG
- OK: Go to 8.
- NG: Replace engine coolant temperature sensor.
- Check Main 12 Causes
If the cause cannot be isolated, Go to MAIN 12 CAUSES OF OVERHEATING .
- Inspection end
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
