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.
Diagnostic Procedure: Notes
- INSPECTION START
Do you have CONSULT-II?
Yes or No
- Yes: GO TO 2.
- No: GO TO 4.
- CHECK COOLING FAN LOW SPEED OPERATION
With CONSULT-II
- Disconnect cooling fan relay-2 and relay-3.
- Turn ignition switch ON.
- Perform "COOLING FAN" in "ACTIVE TEST" mode with CONSULT-II.
- Make sure that cooling fans-1 and -2 operate at low speed.
OK or NG
- OK: GO TO 3.
- NG: Check cooling fan low speed control circuit. (Go to PROCEDURE A .)
- CHECK COOLING FAN HIGH SPEED OPERATION
WITH CONSULT-II
- Turn ignition switch OFF.
- Reconnect cooling fan relay-2 and relay-3.
- Turn ignition switch ON.
- Perform "COOLING FAN" in "ACTIVE TEST" mode with CONSULT-II.
- Make sure that cooling fan-1 operates at high speed.
OK or NG
- OK: GO TO 6.
- NG: Check cooling fan high speed control circuit. (Go to PROCEDURE B .)
- CHECK COOLING FAN LOW SPEED OPERATION
Without CONSULT-II
- Disconnect cooling fan relay-2 and relay-3.
- Start engine and let it idle.
- Set temperature lever at full cold position.
- Turn air conditioner switch ON.
- Turn blower fan switch ON.
- Make sure that cooling fans-1 and -2 operate at low speed.
OK or NG
- OK: GO TO 5.
- NG: Check cooling fan low speed control circuit. (Go to PROCEDURE A .)
- CHECK COOLING FAN HIGH SPEED OPERATION
Without CONSULT-II
- Turn ignition switch OFF.
- Reconnect cooling fan relay-2 and relay-3.
- Turn air conditioner switch and blower fan switch OFF.
- Disconnect engine coolant temperature sensor harness connector.
- Connect 150Ω resistor to engine coolant temperature sensor harness connector.
- Restart engine and make sure that cooling fan-1 operates at high speed.
OK or NG
- OK: GO TO 6.
- NG: Check cooling fan high speed 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 8.
- NG: GO TO 7.
- DETECT MALFUNCTIONING PART
Check the following for leak.
- Hose
- Radiator
- Water pump (Refer to "WATER PUMP
".)
Repair or replace.
- 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 9.
- 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:
82°C (180°F) [standard]
Valve lift:
More than 8 mm/95°C (0.31 in/203°F)
- Check if valve is closed at 5°C (9°F) below valve opening temperature.
For details, refer to "THERMOSTAT AND THERMOSTAT HOUSING ".
OK or NG
- OK: GO TO 10.
- 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 11.
- 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
Use the Manual With the Right Hardware
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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.
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