For 1990-2009 cars

## Cooling System Description and Operation Gasoline

The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly.

The cooling system includes the following components:

• | A radiator and recovery subsystem

• | Cooling fans

• | A thermostat and housing

• | A coolant pump

• | A coolant pump drive belt

The timing belt drives the coolant pump.

All components must function properly in order for the cooling system to operate. The coolant pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head. When the coolant reaches the operating temperature of the thermostat, the thermostat opens. The coolant then goes back to the radiator where it cools.

This system directs some coolant through the hoses to the heater core. This provides for heating and defrosting. The surge tank is connected to the radiator to recover the coolant displaced by expansion from the high temperatures. The surge tank maintains the correct coolant level.

The cooling system for this vehicle has no radiator cap or filler neck. The coolant is added to the cooling system through the surge tank.

### Radiator

This vehicle has a lightweight tube-and-fin aluminum radiator. Plastic tanks are mounted on the right and the left sides of the radiator core.

On vehicles equipped with automatic transaxles, the transaxle fluid cooler lines run through the left radiator tank. A radiator drain cock is on this radiator.

To drain the cooling system, open the drain cock.

### Surge Tank

The surge tank is a transparent plastic reservoir, similar to the windshield washer reservoir.

The surge tank is connected to the radiator by a hose and to the engine cooling system by another hose. As the vehicle is driven, the engine coolant heats and expands. The portion of the engine coolant displaced by this expansion flows from the radiator and the engine into the surge tank. The air trapped in the radiator and the engine is degassed into the surge tank.

When the engine stops, the engine coolant cools and contracts. The displaced engine coolant is then drawn back into the radiator and the engine. This keeps the radiator filled with the coolant to the desired level at all times and increases the cooling efficiency.

Maintain the coolant level between the MIN and the MAX marks on the surge tank when the system is cold.

### Water Pump

The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The water pump is mounted on the front of the transverse-mounted engine, and is driven by the timing belt.

The impeller is supported by a completely sealed bearing.

The water pump is serviced as an assembly and, therefore, cannot be disassembled.

### Thermostat

A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The thermostat is mounted in the thermostat housing to the front of the cylinder head.

The thermostat stops the flow of the engine coolant from the engine to the radiator in order to provide faster warm-up, and to regulate the coolant temperature. The thermostat remains closed while the engine coolant is cold, preventing circulation of the engine coolant through the radiator. At this point, the engine coolant is allowed to circulate only throughout the heater core to warm it quickly and evenly.

As the engine warms, the thermostat opens. This allows the engine coolant to flow through the radiator, where the heat is dissipated through the radiator. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits.

The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.

As the vehicle is driven and the engine warms, the engine coolant temperature increases. When the engine coolant reaches a specified temperature, the wax pellet element in the thermostat expands and exerts pressure against the metal case, forcing the valve open. This allows the engine coolant to flow through the engine cooling system and cool the engine.

As the wax pellet cools, the contraction allows a spring to close the valve.

The thermostat begins to open at 87°C (189°F) and is fully open at 102°C (216°F). The thermostat closes at 86°C (187°F).

### Electric Cooling Fan

Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.

Caution: If a fan blade is bent or damaged in any way, do not repair or reuse the damaged part. Always replace a bent or damaged fan blade. Fan blades that have been damaged can not be assured of proper balance and could fail and fly apart during subsequent use. This creates an extremely dangerous situation.

The fan blades must remain in proper balance. You cannot assure fan blade balance once a fan blade has been bent or damaged. A fan blade that is not in proper balance could fail and fly apart during use, creating an extremely dangerous situation.

The cooling fans are mounted behind the radiator in the engine compartment. The electric cooling fans increase the flow of air across the radiator fins and across the condenser on air condition-equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds.

The main fan size is 300 mm (11.8 in) in diameter with 5 blades to aid the air flow through the radiator and the condenser. An electric motor attached to the radiator support drives the fan.

Air conditioning (A/C) models have 2 fans:

• | The main fan

• | The auxiliary fan

The auxiliary fan is 300 mm (11.8 in) in diameter. Non-air conditioned models have only the main fan.

#### A/C OFF or Non-Air Conditioned Model, 1.4L/1.6L Engine -- North America

• | The cooling fans are actuated by the electronic control module using a low-speed cooling fan relay and a high-speed cooling fan relay. On air conditioned-equipped vehicles, a series/parallel cooling fan relay is also used.

• | The electronic control module will turn the cooling fans ON at low speed when the coolant temperature reaches 93°C (199°F) and at high speed when the coolant temperature reaches 97°C (207°F).

• | The electronic control module will change the cooling fans from high speed to low speed at 94°C (201°F) and will turn the cooling fans OFF at 90°C (194°F).

#### A/C OFF or Non-Air Conditioned Model, 1.4L/1.6L Engine -- European and Non-European

• | The cooling fans are actuated by the electronic control module using a low-speed cooling fan relay and a high-speed cooling fan relay. On air conditioned-equipped vehicles, a series/parallel cooling fan relay is also used.

• | The electronic control module will turn the cooling fans ON at low speed when the coolant temperature reaches 97°C (207.5°F) and at high speed when the coolant temperature reaches 101.25°C (214°F).

• | The electronic control module will change the cooling fans from high speed to low speed at 99°C (210°F) and will turn the cooling fans OFF at 95.25°C (203.4°F).

#### A/C OFF or Non-Air Conditioned Model, 1.8L Engine

• | The cooling fans are actuated by the electronic control module using a low-speed cooling fan relay and a high-speed cooling fan relay. On air conditioned-equipped vehicles, a series/parallel cooling fan relay is also used.

• | The electronic control module will turn the cooling fans ON at low speed when the coolant temperature reaches 93°C (199°F) and at high speed when the coolant temperature reaches 90°C (194°F).

• | The electronic control module will change the cooling fans from high speed to low speed at 94°C (201°F) and will turn the cooling fans OFF at 90°C (194°F).

#### A/C ON, 1.4L/1.6L Engine -- North America

• | The electronic control module will turn the cooling fans ON at low speed when the A/C system is ON. The electronic control module will change to high speed when the coolant temperature reaches 115°C (239°F) or the high side A/C pressure reaches 1 859 kPa (270 psi).

• | The cooling fans will return to low speed when the coolant temperature reaches 113°C (235°F) and the high side A/C pressure reaches 1 449 kPa (210 psi).

#### A/C ON, 1.4L/1.6L Engine -- European and Non-European

• | The electronic control module will turn the cooling fans ON at low speed when the A/C system is ON. The electronic control module will change to high speed when the coolant temperature reaches 101.25°C (214°F) or the high side A/C pressure reaches 1 859 kPa (270 psi).

• | The cooling fans will return to low speed when the coolant temperature reaches 99°C (210°F) and the high side A/C pressure reaches 1 449 kPa (210 psi).

#### A/C ON, 1.8L Engine -- North America

• | The electronic control module will turn the cooling fans ON at low speed when the A/C system is ON. The electronic control module will change to high speed when the coolant temperature reaches 115°C (239°F) or the high side A/C pressure reaches 1 859 kPa (270 psi).

• | The cooling fans will return to low speed when the coolant temperature reaches 113°C (235°F) and the high side A/C pressure reaches 1 449 kPa (210 psi).

#### A/C ON, 1.8L Engine -- European and Non-European

• | The electronic control module will turn the cooling fans ON at low speed when the A/C system is ON. The electronic control module will change to high speed when the coolant temperature reaches 97°C (207°F) or the high side A/C pressure reaches 1 859 kPa (270 psi).

• | The cooling fans will return to low speed when the coolant temperature reaches 94°C (201°F) and the high side A/C pressure reaches 1 449 kPa (210 psi).

### Engine Block Heater

The vehicle is designed to accept an engine block heater that helps to warm the engine and to improve starting in cold weather. It also can help to reduce fuel consumption while a cold engine warms up.

The engine block heater is located under the intake manifold and uses an existing expansion plug for installation.

## Cooling System Description and Operation Diesel

### Cooling System

The cooling system’s function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly. Refer to the following illustration for the components in the system and the basic flow path of the coolant.

(1) | Surge Tank
(2) | Water Pump
(3) | Engine Oil Cooler
(4) | Heater Core
(5) | Water Pipe
(6) | Automatic Transaxle
(7) | EGR Cooler
(8) | Radiator
(9) | Charge Air Cooler
(10) | A/C Condenser
(11) | Auxiliary Cooling Fan
(12) | Main Cooling Fan
(13) | Thermostat

### Water Pump

The water pump is a component of the engine cooling system and circulates the coolant from each of the cooling system components. The water pump consists of a sealing, bearing, pulley (3) and housing (2) and is driven by the timing belt.

The water pump is not the open impeller type but the closed plastic impeller type to increase the cooling efficiency.

### Thermostat

The thermostat controls coolant flow and is assembled on the intake manifold. Coolant temperatures will cause the wax pellet (7) to expand and contract and allow coolant to flow through the system. When cool, the thermostat spring will mechanically close the coolant passage.

The thermostat begins to open at 80°C (176°F) and fully open at 95°C (203°F). The thermostat closes at 75°C (167°F).

### Radiator

The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin cross-flow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere.

The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.

The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes the drain cock and drain cock seal.

The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.

### Surge Tank

The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to expand and contract. The surge tank provides a coolant fill point and a central air bleed location.

During vehicle use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant with bubbles.

### Cooling Fan

The cooling fans are mounted behind the radiator in the engine compartment. The engine cooling fan is driven by electric power. The cooling fan draws air through the radiator to improve the transfer of heat from the coolant to the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and across the condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds.