RM38N0EC _51 Engine / Hybrid System _111791 M20C-FKS, M20D-FKS COOLING _0503631 RADIATOR G

M20C-FKS, M20D-FKS COOLING RADIATOR ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:: ·

Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

·

To prevent burns, do not touch the engine or other high temperature components while the engine is hot.

PROCEDURE

Hide Display 16401 1.CHECK RADIATOR CAP SUB-ASSEMBLY

CAUTION:: Do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

0.479,1.031 0.698,1.229 0.219,0.198 10 false *a 0.708,1.333 1.021,1.49 0.313,0.156 10 false *b 1,1.604 1.313,1.76 0.313,0.156 10 false *c 2.344,1.573 2.656,1.729 0.313,0.156 10 false *d

*a	Rubber Packing (1)
*b	Rubber Packing (2)
*c	Rubber Packing (3)
*d	Valve Seat

Measure the valve opening pressure.

If there are water stains or foreign matter on the rubber packing (1), (2) or (3), clean the part(s) with water and finger scouring.

ii.

Check that the rubber packings (1), (2) and (3) are not deformed, cracked or swollen.

iii.

Check that the rubber packing (3) and valve seat are not stuck together.

iv.

Apply engine coolant to the rubber packings (2) and (3) before using a radiator cap tester.

0.375,0.896 0.375,1.521 false 1.719,0.823 1.885,0.365 1.885,0.365 2.094,0.365 false 2.146,0.281 2.323,0.479 0.177,0.198 10 false *a 1.333,0.958 1.531,1.146 0.198,0.188 10 true *b 0.302,1.573 0.479,1.771 0.177,0.198 10 false *1

*1	Radiator Cap Sub-assembly
*a	Radiator Cap Tester
*b	30° or more

When using the radiator cap tester, tilt it upward 30° or more.

vi.

Pump the radiator cap tester several times, and check the maximum pressure.

Pumping Speed:: 1 pump per second

Result:

Item	Specified Condition
Standard pressure (for brand-new radiator cap sub-assembly)	74 to 103 kPa (0.8 to 1.1 kgf/cm², 10.7 to 14.9 psi)
Minimum pressure (for used radiator cap sub-assembly)	59 kPa (0.6 kgf/cm², 8.6 psi)

HINT:: Even if the radiator cap sub-assembly cannot maintain the maximum pressure, it is not a defect.

If the maximum pressure is less than the minimum pressure, replace the radiator cap sub-assembly.

Hide Display 2.CHECK RADIATOR ASSEMBLY FOR CLOGGING

CAUTION:: To prevent burns, do not touch the engine or other high temperature components while the engine is hot.

Remove the front bumper assembly.

for SFTM Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for SFTM Made)>REMOVAL202111,202303,_59,_111849,_0500095,RM100000001Z1C1,202303,999999,_59,_111849,_0500095,RM100000002AYNE,

for GTMC Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REMOVAL202203,202303,_59,_111849,_0524334,RM100000002208Z,202303,999999,_59,_111849,_0524334,RM100000002AYNC,

Remove the inlet air cleaner assembly.

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Remove the upper radiator air guide plate.

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Shine an electric light at the radiator assembly from the front and check the radiator assembly for clogging using a mirror.

1.156,0.542 1.563,0.542 false 2.208,0.542 2.896,0.542 false 5.198,0.865 5.667,0.99 5.667,0.99 5.177,1.292 false 4.302,0.927 3.885,1 3.885,1 4.354,1.292 false 1.677,2.167 1.927,2.385 0.25,0.219 10 true *a 3.823,2.167 4.073,2.375 0.25,0.208 10 true *b 1,0.448 1.313,0.604 0.313,0.156 10 false *c 2.948,0.448 3.26,0.604 0.313,0.156 10 false *d 5.708,0.906 5.99,1.115 0.281,0.208 10 true *e 3.698,0.906 4.01,1.063 0.313,0.156 10 false *e

*a	OK	*b	NG
*c	Electric Light	*d	Mirror
*e	Areas to be checked	-	-

OK:: The radiator assembly is not clogged.

If the radiator assembly is clogged, clean it.

Install the upper radiator air guide plate.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (COOLING)>RADIATOR>INSTALLATION202203,999999,_51,_111791,_0503631,RM1000000022L3I_01_0209,

Install the inlet air cleaner assembly.

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Install the front bumper assembly.

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for GTMC Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>INSTALLATION202203,202303,_59,_111849,_0524334,RM1000000022092,202303,999999,_59,_111849,_0524334,RM100000002AYND,

Hide Display 3.CLEAN RADIATOR ASSEMBLY

CAUTION:: To prevent burns, do not touch the engine or other high temperature components while the engine is hot.

Remove the upper radiator support sub-assembly.

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Cover the opening of each air duct with a piece of cloth.

Clean the cooler condenser assembly.

Check that the washer nozzle is not clogged.

ii.

Insert the washer nozzle into the space in front and spray it.

NOTICE:: ·

Clean the fins of the cooler condenser assembly by spraying the entire area for 150 seconds. Repeat this process twice.

·

Set the air pressure to 0.4 MPa (4.1 kgf/cm², 58 psi).

·

Check that water sprays in mist form from the washer nozzle.

·

Keep the washer nozzle parallel to the cooler condenser assembly.

·

Do not allow the washer nozzle to contact the fins of the cooler condenser assembly.

·

Keep the washer nozzle moving while spraying water.

·

Do not spray the cooler compressor assembly or generator assembly excessively.

iii.

Leave the cooler condenser assembly as is for 10 minutes to let the water penetrate the dirt.

iv.

Clean the cooler condenser assembly again.

NOTICE:: ·

Clean the fins of the cooler condenser assembly by spraying the entire area for 150 seconds. Repeat this process 4 times.

·

Set the air pressure to 0.4 MPa (4.1 kgf/cm², 58 psi).

·

Check that water sprays in mist form from the washer nozzle.

·

Keep the washer nozzle parallel to the cooler condenser assembly.

·

Do not allow the washer nozzle to contact the fins of the cooler condenser assembly.

·

Keep the washer nozzle moving while spraying water.

·

Do not spray the cooler compressor assembly or generator assembly excessively.

Using an air blow gun, dry the cooler condenser assembly for 3 minutes.

Disengage the claw and raise the lock lever to disconnect the cooling fan motor connector as shown in the illustration.

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Lock Lever

NOTICE:: After disconnecting the cooling fan motor connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the cooling fan motor connector.

Disengage the 2 clamps to disconnect the wire harness from the fan with motor assembly.

Disengage the 2 claws and separate the fan with motor assembly from the radiator assembly.

Clean the radiator assembly.

Insert the washer nozzle between the radiator assembly and fan with motor assembly and spray the radiator assembly.

NOTICE:: ·

Clean the fins of the radiator assembly by spraying the entire area for 150 seconds. Repeat this process twice.

·

Set the air pressure to 0.4 MPa (4.1 kgf/cm², 58 psi).

·

Check that water sprays in mist form from the washer nozzle.

·

Keep the washer nozzle parallel to the radiator assembly.

·

Do not allow the washer nozzle to contact the fins of the radiator assembly.

·

Keep the washer nozzle moving while spraying water.

ii.

Leave the radiator assembly as is for 10 minutes to let the water penetrate the dirt.

iii.

Clean the radiator assembly again.

NOTICE:: ·

Clean the fins of the radiator assembly by spraying the entire area for 150 seconds. Repeat this process 4 times.

·

Set the air pressure to 0.4 MPa (4.1 kgf/cm², 58 psi).

·

Check that water sprays in mist form from the washer nozzle.

·

Keep the washer nozzle parallel to the radiator assembly.

·

Do not allow the washer nozzle to contact the fins of the radiator assembly.

·

Keep the washer nozzle moving while spraying water.

iv.

Using an air blow gun, dry the radiator assembly for 3 minutes.

Check the fins of the radiator assembly for clogs again.

If the radiator assembly is clogged, clean the radiator assembly and cooler condenser assembly again.

Check that the 2 guides at the bottom are engaged to the radiator assembly.

Engage the 2 claws to install the fan with motor assembly to the radiator assembly.

Engage the 2 clamps to connect the wire harness to the fan with motor assembly.

4.667,0.75 4.823,0.49 4.823,0.49 4.979,0.49 false 5.021,0.406 5.344,0.667 0.323,0.26 10 false *a

Lock Lever

Connect the cooling fan motor connector and push down the lock lever to engage the claw as shown in the illustration.

NOTICE:: ·

When connecting the cooling fan motor connector, make sure that the connecting parts of the cooling fan motor connector are free of dirt, water or other foreign matter.

·

Be sure to securely connect the cooling fan motor connector.

Remove the piece of cloth from the opening of each air duct.

Install the upper radiator support sub-assembly.

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