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.

Water Temperature Control Assembly

Repair procedures Removal 1.Disconnect the battery negative terminal. 2.Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover") ...

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