Right, been doing a bit of research and found a PDF file, and in particular the cooling section. This may be a long post but I think it will be more concise and hopefully help others to diagnose cooling issues. Some of the references to other sections aren't detailed here but I could make another post and link to it if need be, or just add the referenced sections on the bottom of this post. if you need the images I can upload them onto the end of this post.
COOLANT CHECK AND REPLACEMENT
CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK
The engine coolant level should be between the "LOW" and "FULL" lines.
If low, check for leaks and add engine coolant up to the "FULL" line.
[*]CHECK ENGINE COOLANT QUALITY
There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolantshould be free from oil.
If excessively dirty, replace the coolant.
[*]REPLACE ENGINE COOLANT
Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
Loosen the 2 drain plugs (for the engine and radiator), and drain the coolant.
Close the drain plugs. (Torque:29 Nm (300 kgf cm, 22 ft lbf) for engine
Slowly fill the system with coolant. Use a good brand of ethylene–glycol base coolant and mix it according to the manufacturer's directions. Using coolant which includes more than 50 % ethylene–glycol (but not more than 70 %) is recommended. NOTICE: Do not use an alcohol type coolant. The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 7.5 liters (7.9 US qts, 6.6 lmp. qts)
Install the radiator cap.
Start the engine, and bleed the cooling system.
Refill the reservoir tank with coolant until it reaches the "FULL" line.
THERMOSTAT REMOVAL
Installation is in reverse order of removal.
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. (I think what this actually means is 'don't permanently remove the thermostat)
DRAIN ENGINE COOLANT
DISCONNECT WATER INLET FROM WATER PUMP, AND REMOVE THERMOSTAT
Remove the 2 nuts holding the water inlet to the water pump, and disconnect the water inlet from the water pump. Torque: 8.8 Nm (90 kgf cm, 78 in.lbf)
Remove the thermostat.
Remove the gasket from the thermostat. INSTALLATION HINT: See water pump installation.
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve opening temperature.
Immerse the thermostat in water and gradually heat the water.
Check the valve opening temperature. Valve opening temperature: 80–84°C (176–183°F) If the valve opening temperature is not as specified, replace the thermostat.
Check the valve lift. Valve lift: 8.5 mm (0.335 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat.
Check that the valve spring is tight when the thermostat is fully closed. If not closed, replace the thermostat.
WATER PUMP REMOVAL
DRAIN ENGINE COOLANT
REMOVE ENGINE UNDER COVER
REMOVE AIR CLEANER DUCT
REMOVE AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE
REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY
Loosen the 4 nuts holding the fluid coupling to the water pump.
Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt.
Remove the 4 nuts, fluid coupling and water pump pulley.
[*]REMOVE RADIATOR ASSEMBLY (See steps 5 and 6 in radiator removal)
[*]REMOVE WATER INLET AND THERMOSTAT
Remove the 2 nuts holding the water inlet to the water pump, and disconnect the water inlet from the water pump.
Remove the thermostat.
Remove the gasket from the thermostat.
[*]REMOVE DISTRIBUTOR (See distributor removal in Ignition System)
[*]REMOVE WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE
Remove the 2 bolts, water bypass outlet and No.1 water bypass pipe.
Remove the 3 O–rings from the water bypass outlet and No.1 water bypass pipe.
[*]REMOVE TIMING BELT (See steps 6 to 10 and 12 to 16 in timing belt removal in Engine Mechanical)
[*]REMOVE IDLER PULLEY (See step 17 in timing belt removal in Engine Mechanical)
[*]REMOVE WATER PUMP
Remove the mounting bolt, and disconnect the engine wire bracket.
Loosen the generator mounting nut.
Remove the generator mounting bolt, and disconnect the generator from the water pump.
Remove the 2 nuts, and disconnect the No.2 water bypass pipe from the water pump.
Remove the 6 bolts, water pump and gasket.
Remove the O–ring from the cylinder block.
WATER PUMP COMPONENTS INSPECTION
INSPECT WATER PUMP
Turn the pulley seat, and check that the water pump bearing is not rough or noisy.If necessary, replace the water pump.
INSPECT FLUID COUPLING
Remove the 4 nuts and fan from the fluid coupling.
Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling.
Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgf cm, 65 in. lbf)
WATER PUMP INSTALLATION
INSTALL WATER PUMP
Install a new O–ring to the cylinder block.
Install a new gasket to the water pump.
Connect the water pump to the water bypass pipe. Do not install the nut yet.
Install the water pump with the 2 bolts (A) and 4 bolts ( B) . Torque: 21 Nm (210 kgf cm, 15 ft lbf)
HINT: Hand tighten the (A) bolts first.
Install the 2 nuts holding the No.2 water bypass pipe to the water pump. Torque: 21 Nm (210 kgf cm, 15 ft lbf)
Install the generator mounting bolt. Torque: 37 Nm (380 kgf cm, 27 ft lbf)
Tighten the generator mounting nut. Torque: 37 Nm (380 kgfcm, 27 ftlbf)
Install the engine wire bracket with the bolt.
[*]INSTALL IDLER PULLEY (See step 2 in timing belt installation in Engine Mechanical)
INSTALL TIMING BELT (See steps 3 to 7 and 9 to 16 in timing belt installation in Engine Mechanical)
INSTALL WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE
Install 2 new O–rings to the No.1 water bypass pipe.
Install a new O–ring and the water bypass outlet with the 2 bolts. Torque: 8.8 Nm (90 kgf cm, 78 in. lbf)
INSTALL DISTRIBUTOR (See steps 3 and 5 to 6 distributor installation in Ignition System)
PLACE THERMOSTAT IN WATER INLET
Install a new gasket to the thermostat.
Align the jiggle valve of the thermostat with the protrusion of the water inlet.
[*]INSTALL WATER INLET
Install the water inlet with the 2 nuts. Torque: 8.8 N⋅m (90 kgf⋅cm, 78 in.⋅lbf)
[*]INSTALL RADIATOR ASSEMBLY (See steps 4 and 5 in radiator installation)
[*]INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT
Align the matchmarks, and install the water pump pulley and fan fluid coupling with the 4 nuts.
Install the drive belt by turning the drive belt tensioner clockwise.
Stretch the belt tight and tighten the 4 nuts. Torque: 16 N⋅m (165 kgf⋅cm, 12 ft⋅lbf)
[*]INSTALL AIR CLEANER, VAF METER AND INTAKE AIR CONNECTOR PIPE
[*]INSTALL AIR CLEANER DUCT
[*]FILL WITH ENGINE COOLANT
[*]START ENGINE AND CHECK FOR LEAKS
[*]CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
[*]CHECK IGNITION TIMING (See ignition timing inspection and adjustment in Engine Mechanical)
[*]INSTALL ENGINE UNDER COVER
[*]ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
[*]RECHECK ENGINE COOLANT LEVEL ENGINE COOLING SYSTEM
ELECTRIC COOLING FAN (On–Vehicle Inspection)
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 88C (190F)
Turn the ignition switch ON.
Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch.
Disconnect the ECT switch connector.
Check that the cooling fan rotates. If not, check the fan main relay, cooling fan relay, cooling fan, fuses, and check for short circuit between the cooling fan relay and ECT switch. Reconnect the ECT switch connector.
[*]CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 97C (207F)
Start the engine, and raise coolant temperature to above 97C (207F)
Check that the cooling fan rotates If not, replace the ECT switch.
COOLING FAN INSPECTION
INSPECT COOLING FAN
Disconnect the fan connector.
Connect battery and ammeter to the cooling fan connector.
Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 6.0–7.4 A
Reconnect the fan connector
COOLING FAN REMOVAL (Installation is in the reverse order of removal)
REMOVE ENGINE UNDER COVER
REMOVE AIR CLEANER DUCT
DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR
REMOVE COOLING FAN
Disconnect the cooling fan connector.
Disconnect the ECT switch wire from the wire clamp
Remove the 3 bolts and cooling fan.
COMPONENTS FOR DISASSEMBLY AND ASSEMBLY
COOLING FAN DISASSEMBLY (Assembly is in the reverse order of disassembly)
REMOVE FAN
REMOVE FAN MOTOR
Disconnect the wire and connector from the fan shroud.
Remove the 3 screws and fan motor.
Engine Coolant Temperature (ECT) Switch ECT SWITCH INSPECTION
REMOVE ENGINE UNDER COVER
DRAIN ENGINE COOLANT
REMOVE ECT SWITCH
Disconnect the ECT switch connector.
Remove the ECT switch.
Remove the O–ring the ECT switch.
[*]INSPECT ECT SWITCH
Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 101C (214F)
Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is below 91C (196F) If continuity is not as specified, replace the switch.
[*]REINSTALL ECT SWITCH
Install a new O–ring to the ECT switch.
Apply soapy water on the O–ring.
Install the ECT switch. Torque: 7.4 N⋅m (75 kgf⋅cm, 65 in.⋅lbf)
Connect the ECT switch connector.
[*]REFILL WITH ENGINE COOLANT
[*]START ENGINE AND CHECK FOR LEAKS
[*]REINSTALL ENGINE UNDER COVER
Fan Main Relay ("RDI FAN MAIN") FAN MAIN RELAY INSPECTION
REMOVE RELAY BOX COVER
REMOVE FAN MAIN RELAY
INSPECT FAN MAIN RELAYInspect relay continuity
Using an ohmmeter, check that there is continuity between terminals 3 and 5.
Check that there is continuity between terminals 2 and 4.
Check that there is no continuity between terminals 1 and 4. If continuity is not as specified, replace the relay.
Inspect relay operation
Apply battery voltage across terminals 3 and 5.
Using an ohmmeter, check that there is no continuity between terminals 2 and 4.
Check that there is continuity between terminals 1 and 2. If operation is not as specified, replace the relay.
[*]REINSTALL FAN MAIN RELAY
[*]REINSTALL RELAY BOX COVER
Cooling Fan Relay ("RDI FAN") COOLING FAN RELAY INSPECTION
REMOVE RELAY BOX COVER
REMOVE COOLING FAN RELAY
INSPECT COOLING FAN RELAYInspect relay continuity
Using an ohmmeter, check that there is continuity between terminals 1 and 2.
Check that there is continuity between terminals 3 and 4. If continuity is not as specified, replace the relay.
[*]Inspect relay operation
Apply battery voltage across terminals 1 and 2.
Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If operation is not as specified, replace the relay.
[*]REINSTALL COOLING FAN RELAY
[*]REINSTALL RELAY BOX COVER
RADIATOR REMOVAL
REMOVE ENGINE UNDER COVER
DRAIN ENGINE COOLANT
REMOVE AIR CLEANER DUCT
REMOVE NO.2 FAN SHROUD
Remove the 2 clips.
Disconnect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud, and remove the No.2 fan shroud.
[*]DISCONNECT HOSES FROM RADIATOR Disconnect these hoses from the radiator:
Reservoir tank inlet hose
Upper radiator hose
Lower radiator hose
2 A/T oil cooler hoses (Plug the hose ends)
[*]REMOVE RADIATOR ASSEMBLY
Disconnect the ECT switch for electric cooling fan connector and wire.
Disconnect the electric cooling fan connector and wire.
Remove the nut and upper radiator support. Remove the 2 upper radiator supports.
Lift out the radiator assembly.
Remove the 2 lower radiator supports.
[*]REMOVE ELECTRIC COOLING FAN FROM RADIATOR
[*]REMOVE NO.1 FAN SHROUD FROM RADIATOR
Remove the 2 bolts.
Disconnect the lower sides of the No.1 fan shroud from the 2 hooks of the radiator, and remove the radiator.
Remove the 2 cushions from the No.1 fan shroud.
[*]REMOVE ENGINE COOLANT TEMPERATURE (ECT) SWITCH FROM RADIATOR
Remove the ECT switch.
Remove the O–ring from the ECT switch
RADIATOR INSTALLATION
INSTALL ENGINE COOLANT TEMPERATURE (ECT) SWITCH TO RADIATOR
Install a new O–ring to the ECT switch.
Apply soapy water to the O–ring.
Install the ECT switch. Torque: 7.4 N⋅m (75 kgf⋅cm, 65 in.⋅lbf)
[*]INSTALL NO.1 FAN SHROUD TO RADIATOR
Install the 2 cushions to the radiator.
Connect the lower sides of the No.1 fan shroud to the 2 hooks of the radiator.
Install the No.1 fan shroud with the 2 bolts.
[*]INSTALL ELECTRIC COOLING FAN TO RADIATOR
[*]INSTALL RADIATOR ASSEMBLY
Install the 2 lower radiator supports to the radiator.
Place the radiator assembly on the body bracket.
Install the radiator with the 2 upper radiator supports and 2 nuts. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) HINT: After installation, check that the rubber cushion (A) of the support is not depressed.
Connect the electric cooling fan connector and wire.
Connect the ECT switch (for electric cooling fan) connector and wire.
[*]CONNECT HOSES TO RADIATOR
[*]INSTALL NO.2 FAN SHROUD
Connect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud.
Install the No.2 fan shroud with the 2 clips.
[*]INSTALL AIR CLEANER DUCT
[*]FILL WITH ENGINE COOLANT
[*]CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
[*]START ENGINE AND CHECK FOR LEAKS
[*]INSTALL ENGINE UNDER COVER