Kia Picanto: Cooling System / Thermostat

Kia Picanto JA 2017-2024 Service & Repair Manual / Engine Mechanical System / Cooling System / Thermostat

Repair procedures

Removal And Installation

Thermostat

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.

1.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

2.	Drain the coolant. (Refer to Cooling System - "Coolant")

3.	Disconnect the radiator lower hose (A).

4.	Remove the drive belt. (Refer to Drive Belt System - "Drive Belt")

5.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

Remove the water inlet fitting (A).

Tightening torque :

18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)

7.	Remove the thermostat (A).

Install in the reverse order of removal.

•	Install the thermostat with the jiggle valve upward.

•	When assembling the thermostat, place the thermostat on the housing with a protrusion of thermostat matching with a groove of the housing and install the inlet fitting. Be careful the thermostat doesn’t get out of the groove on the housing.

•	Clean surface on the rubber packing contact surface.

9.	Fill the engine coolant. (Refer to Cooling System - "Coolant")

10.	Start the engine and check for leaks.

11.	Recheck the coolant level.

Heater Pipe

1.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

2.	Drain the coolant. (Refer to Cooling System - "Coolant")

3.	Disconnect the heater hose (A).

4.	Remove the intake manifold. (Refer to Intake and Exhaust - "Intake Manifold")

5.	Disconnect the water hose.

6.	Remove the alternator. (Refer to Engine Electrical System -"Alternator")

Remove the heater pipe and hose (A).

Tightening torque :

Bolt (B) :

9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

Bolt (C) :

19.6 - 26.5 N·m (2.0 - 2.7 kgf·m, 14.5 - 19.5 lb·ft)

8.	Install in the reverse order of removal.

9.	Fill the engine coolant. (Refer to Cooling System - "Coolant")

10.	Start the engine and check for leaks.

11.	Recheck the coolant level.

Inspection

Immerse thermostat in water heated to over 95°C (203°F), then heat for at least 3 minutes to check valve lift.

•	Do not use water below 95°C (203°F).

•	Do not directly heat unit as this will damage thermostat.

Check the valve opening temperature.

Valve opening temperature:

86.5 - 89.5°C (187.7 - 193.1°F)

Full opening temperature: 100°C (212°F)

Check the valve lift.

Valve lift : 8 mm (0.3 in) or more at 100°C (212°F)

Troubleshooting

Symptoms

Possible Causes

Remedy

Coolant leakage

•	From the thermostat gasket

Check the mounting bolts

•	Check the torque of the mounting bolts

•	Retighten the bolts and check for leakage again.

Check the gasket for damage

•	Check gasket or seal for damage

•	Replace gaskets and reuse the thermostat.

Cooled excessively

•	Low heater performance (cool air blows out)

•	Thermogauge indicates 'LOW'

Visually check after removing the radiator cap.

•	Insufficient coolant or leakage.

•	After refilling coolant, recheck.

Check KDS & start engine

•	Check DTCs

•	Check connection of the fan clutch or the fan motor.

※ If the fan clutch is always connected, there will be a noise at idle.

•	Check the engine coolant sensor, wiring and connectors.

•	Replace the components.

Remove the thermostat and inspect

•	Check for dust or chips in the thermostat valve.

•	Check for sticky thermostat valve.

•	Clean the thermostat valve and reuse the thermostat.

•	Replace the thermostat, if it doesn't work properly.

Heated excessively

•	Engine overheated

•	Thermogauge indicates 'HI'

Visually check after removing the radiator cap.

•	Insufficient coolant or leakage. ※ Be careful when removing the radiator cap from an overheated vehicle.

•	Check air in cooling system.

•	After refilling coolant, recheck.

•	Check the cylinder head gaskets for damage and the tightening torque of the mounting bolts.

Check KDS & start engine

•	Check DTCs

•	Check the fan motor performance as temperature varies.

•	Check if the fan clutch slips.

•	Check for sticky water pump or damaged impeller.

•	Check the engine coolant sensor, wiring and connectors.

•	Check the fan motor, the relay and the connector.

•	Replace the fan clutch, if it doesn't work properly.

•	Replace the water pump, if it doesn't work properly.

Immerse the thermostat in boiling water and inspect.

•	Check that the thermostat opens at the valve opening temperature.

※ ※ Check that the thermostat opens at the valve opening temperature.

•	Replace the thermostat, if it doesn't work properly.

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