SERVICE MANUAL

DAIHATSU

V116,V118,V119
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COOLING SYSTEM

CONTENTS
CHECK AND CHANGE OF ENGINE COOLANT ........................................................ CO–2
WATER PUMP ............................................................................................................. CO–2
COMPONENTS ....................................................................................................... CO–2
WATER PUMP ......................................................................................................... CO–2
IN-VEHICLE INSPECTION ...................................................................................... CO–2
REMOVAL OF WATER PUMP ................................................................................. CO–2
INSPECTION OF WATER PUMP COMPONENTS ................................................... CO–3
INSTALLATION OF WATER PUMP .......................................................................... CO–3
THERMOSTAT ............................................................................................................. CO–5
COMPONENTS ....................................................................................................... CO–5
REMOVAL OF THERMOSTAT ................................................................................. CO–5
INSPECTION OF THERMOSTAT ............................................................................. CO–6
INSTALLATION OF THERMOSTAT ......................................................................... CO–6
TIGHTNING TORQUE ................................................................................................. CO–7
VCO00001-00000
CO–2
CHECK AND CHANGE OF ENGINE COOLANT
Refer to MA section.
VCO00002-00000

WATER PUMP
COMPONENTS

w
r

q T : Tightening torque
Unit : N·m (kg-m)
u ★ : Non-reusable part
★t y★
q Pulley seal
w Water pump body
e Water pump bearing retaining wire
r Water pump seal set
e t Water pump rotor
y Gasket
u Water pump cover

VCO00003-00001

IN-VEHICLE INSPECTION
Perform the coolant leakage check, using a radi-
ator cap tester.
If coolant leakage is present on the water pump,
repair or replace the water pump.
VCO00004-00000

REMOVAL OF WATER PUMP

1. Disconnect the battery ground cable terminal
from the negative terminal of the battery.
2. Drain the coolant. (Refer to MA section)
CAUTION: VCO00005-00002

• Never open the radiator cap or drain plug 4. Remove the alternator drive belt. (Refer to CH
when the engine is still hot. section)

3. Loosen the attaching bolts of the cooling fan.

(Only for models without fluid coupling.)

VCO00006-00003

“To be continued”
 CO–3
5. Remove the fan, fan spacer and pulley by re-
moving the attaching bolts.
(Only for models without fluid coupling.)

VCO00010-00006

2. Inspection of fluid coupling

When the fluid coupling is heated, using hair
VCO00007-00004 dryer or the like, ensure that the rotation resis-
6. Remove the fan from the fluid coupling by re- tance will be increased according to the fluid
moving its attaching nuts. coupling temperature without being caught.
(Only for models with fluid coupling.)
7. Remove the fluid coupling and water pump
pulley by removing its attaching nuts.
(Only for models with fluid coupling.)
VCO00008-00000

8. Remove the water pump attaching bolts.

9. Remove the water pump and gasket by dis-
connecting the radiator hose and by-pass
hose.

VCO00011-00007

INSTALLATION OF WATER PUMP

1. Clean the water pump attaching surface of the
cylinder block and water pump.
2. Attach the water pump to the cylinder head
with the attaching bolts with a new gasket in-
terposed while connecting the by-pass hose.
3. Tighten the attaching bolt of the water pump
to the specified tightening torque.
VCO00009-00005
Tightening Torque: 25 N·m (2.55 kgf-m)
INSPECTION OF WATER PUMP VCO00012-00000

COMPONENTS 4. Attach new clamps for the by-pass hose.

1. Inspection of water pump 5. Connect the radiator hose to the water pump
Turn the pulley seat and check that the water and attach new hose bands.
pump bearing moves smoothly without any
noise or binding.
If necessary, replace the water pump.

VCO00013-00005

“To be continued”
 CO–4
6. Install the water pump pulley and fluid cou-
pling to the water pump with the attaching
nuts.
Tighten the nuts to the specified tightening
torque.
(Only for models with fluid coupling)
Tightening Torque: 18.5 N·m (1.89 kgf-m)

7. Install the fan to the fluid coupling with the at-

taching nuts.
(Only for models with fluid coupling)
VCO00014-00000

8. Install the water pump pulley, fan spacer and

fan with the attaching bolts temporarily.
(Only for models without fluid coupling)

VCO00015-00004

9. Install the alternator drive belt and adjust the

tension.
(Refer to EM section)
10. Tighten the water pump pulley, fan spacer and
fan attaching bolts.
(Only for models without fluid coupling.)
11. Fill coolant. (Refer to MA section)
CAUTION:
• Never open the radiator cap or drain plug
when the engine is still hot.

12. Connect the battery ground cable terminal to

the negative terminal of the battery.

VCO00016-00003
 CO–5
THERMOSTAT
COMPONENTS

T: 1.56 - 2.34 T : Tightening torque

(11.29 - 16.91) Unit : N·m (kgf-m)
★ : Non-reusable part

q Radiator hose No. 1

w Water outlet
e Thermostat

VCO00017-00008

REMOVAL OF THERMOSTAT
1. Disconnect the battery ground cable terminal
from the negative terminal of the battery.
2. Drain coolant. (Refer to MA section)
CAUTION:
• Never open the radiator cap or drain plug
when the engine is still hot.

3. Disconnect the radiator hose inlet hose from

the water outlet.
VCO00019-00010

5. Remove the thermostat.

6. Remove the gasket from the thermostat.

VCO00018-00009

4. Remove the water outlet by removing the at-

taching bolts.
VCO00020-00011

“To be continued”
CO–6
INSPECTION OF THERMOSTAT
1. Ensure that the thermostat valve is closed
completely at room temperature (20°C) and
that the spring has no play.
Replace the thermostat if the valve is open or
the spring has a play.

VCO00024-00010

4. Connect the radiator hose inlet hose to the

water outlet and attach new hose bands.
5. Fill coolant. (Refer to MA section)
CAUTION:
• Never open the radiator cap or drain
VCO00021-00012 plug when the engine is still hot.
2. Immerse the thermostat in water, and check
the valve opening temperature by heating the 6. Connect the battery ground cable terminal to
water gradually. the negative terminal of the battery.
If the valve operation fails to conform to the
specification, replace the thermostat.
Valve opening Valve lift
Specification
temperautre
10 mm or
82°C type 80.0 - 84.0°C more at 95°C

VCO00025-00009

RADIATOR
For the checking of the radiator, refer to MA sec-
tion.
VCO00026-00000

VCO00022-00013

INSTALLATION OF THERMOSTAT
1. Install a new gasket to the thermostat.
VCO00023-00000

2. Attach the thermostat onto the water outlet

housing.
3. Install the water outlet with the attaching bolts
and tighten them to the specified tightening
torque evenly.
Tightening Torque: 18.5 N·m (1.89 kgf-m)

“To be continued”
 CO–7
TIGHTENING TORQUE
Components N·m kgf-m
Water pump & Cylinder block 25 2.55
Fluid coupling & Water pump 18.5 1.89
Water outlet & Cylinder head 18.5 1.89
VC-00027-00000

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