GROUP 14
ENGINE COOLING
CONTENTS
14-1
GENERAL INFORMATION.............14-2
SERVICE SPECIFICATIONS..........14-2
COOLANT.........................14-2
SEALANT.........................14-3
ENGINE COOLING DIAGNOSIS........14-3
INTRODUCTION....................14-3
TROUBLESHOOTING STRATEGY........14-3
SYMPTOM CHART...................14-3
SYMPTOM PROCEDURES..............14-3
Inspection Procedure 1: Coolant Leak
..................................14-3
Inspection Procedure 2: Engine
Overheating.......................14-4
Inspection Procedure 3: Radiator Fan
and Condenser Fan do not Operate
..................................14-6
COOLING FAN MOTOR CHECK........14-19
THERMOSTAT.....................14-19
REMOVAL AND INSTALLATION.......14-19
INSPECTION.....................14-21
WATER PUMP.....................14-22
REMOVAL AND INSTALLATION.......14-22
WATER HOSE AND WATER PIPE......14-23
REMOVAL AND INSTALLATION.......14-23
INSPECTION.....................14-26
RADIATOR.......................14-27
REMOVAL AND INSTALLATION.......14-27
SPECIAL TOOLS..................14-13
ON-VEHICLE SERVICE.............14-15
ENGINE COOLANT LEAK CHECK......14-15
RADIATOR CAP PRESSURE CHECK....14-15
ENGINE COOLANT REPLACEMENT.....14-15
ENGINE COOLANT CONCENTRATION TEST
...............................14-16
COOLING FAN RELAY CONTINUITY CHECK
...............................14-17
ENGINE COOLING
14-2
GENERAL INFORMATION
GENERAL INFORMATION
｠
The cooling system is designed to keep every part
of the engine at appropriate temperature in
whatever condition the engine may be operated.
The cooling method is of the water-cooled, pressure
forced circulation type in which the water pump
pressurizes coolant and circulates it throughout the
engine. If the coolant temperature exceeds the
prescribed temperature, the thermostat opens to
circulate the coolant through the radiator as well so
CONSTRUCTION DIAGRAM
M11401000001USA0000010000
that the heat absorbed by the coolant may be
radiated into the air. The water pump is of the
centrifugal type and is driven by the drive belt from
the crankshaft. The radiator is the corrugated fin,
down flow type.
｠
PremAir® direct ozone reduction (DOR) radiator
has been adopted to vehicle for California emission
regulation. A catalyst which depollutes ozone (O3)
in the air has been insufflated to the radiator core.
Radiator fan motor
Transmission oil
cooler line hose
and tube assembly
Radiator upper hose
assembly
Radiator assembly
Condenser fan motor
Cooling fan shroud
Radiator condenser
tank assembly
Radiator lower hose
SERVICE SPECIFICATIONS
Item Standard value Limit
Valve opening pressure of radiator cap kPa (psi) 93 - 123 (14 - 18) Minimum 83 (12)
Thermostat Valve opening temperature of thermostat °C (°F) 82 ± 1.5 (180 ± 3) -
Full-opening temperature of thermostat °C (°F) 95 (203) -
Valve lift mm (in) 9.0 (0.35) or more -
ZC6004250001
M11401000049USA0000010000
COOLANT
Item
Long life antifreeze coolant or an equivalent 9.5 (10.0)
Quantity dm3(qt)
10.0 (10.6) <Vehicles with Towing Package
or DOR radiator>
M11401000004USA0000010000
ENGINE COOLING
SEALANT
SEALANT
Item Specified sealant
Engine coolant temperature sensor 3M™ AAD Part No.8731 or equivalent
ENGINE COOLING DIAGNOSIS
INTRODUCTION
The system cools the engine so that it does not
overheat and maintains the engine at an optimum
temperature. The system components are the
radiator, water pump, thermostat, condenser fan
assembly. Possible faults include low coolant,
contamination, belt loosening and component
damage.
TROUBLESHOOTING STRATEGY
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure to find most
of the engine cooling faults.
1.
Gather information from the customer.
2.
Verify that the condition described by the customer
exists.
3.
Find and repair the malfunction by following the
SYMPTOM CHART.
4.
Verify that the malfunction is eliminated.
14-3
M11401000005USA0000010000
M11401000053USA0000010000
M11401000052USA0000010000
SYMPTOM CHART
Symptom Inspection
procedure
Coolant leak 1 P.14-3
Engine overheating 2 P.14-4
Radiator fan and condenser fan do not operate 3 P.14-6
SYMPTOM PROCEDURES
Inspection Procedure 1: Coolant Leak
DIAGNOSIS
STEP 1. Check for coolant leaks.
When pressure testing the cooling system, slowly release
cooling system pressure to avoid getting burned by hot
coolant.
M11401000056USA0000010000
Reference page
M11401000065USA0000010000
14-4
Cap adapter
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
｠
Be sure to completely clean away any moisture from the
places checked.
｠
When the tester is removed, be careful not to spill any
coolant.
｠
When installing and removing the tester and when
testing, be careful not to deform the filler neck of the
radiator.
Check that the coolant level is up to the filler neck. Install a
radiator tester and apply 160 kPa (23 psi) pressure, and then
check for leakage from the radiator hose or connections.
Adapter
Q:Is leakage present from the radiator hose or
connections?
YES: Repair or replace the appropriate part, then go to
Step 2.
NO: There is no action to be taken.
ZC602733
AA00
STEP 2. Retest the system.
Q:It there still coolant leakage?
YES: Return to Step 1.
NO: The procedure is complete.
Inspection Procedure 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant
contamination.
Q:Is the coolant contaminated with rust and oil?
YES: Replace it. Refer to P.14-15.
NO: There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.
NOTE: Be sure that the cap is clean before testing. Rust
or other foreign material on the cap seal will cause an
improper reading.
(1)
Use a cap adapter to attach the cap to the tester.
(2)
Increase the pressure until the gauge indicator stops moving.
Cap adapter
M11401000066USA0000010000
Minimum limit: 83 kPa (12 psi)
Standard value: 93 - 123 kPa (14 - 18 psi)
ZC602734
Q:Does the reading remain at or above the minimum limit?
YES: Go to Step 3.
NO: Replace the radiator cap. Then go to Step 5.
AA00
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
STEP 3. Check thermostat operation.
Refer to P.14-21.
Q:Does the thermostat operate correctly?
YES: Go to Step 4.
NO: Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.
Refer to GROUP 00, Maintenance Service - Drive Belt (For The
Generator, Water Pump and Power Steering Pump) (Check
Condition) P.00-58.
Q:Is the drive belt loose or damaged?
YES: Adjust or replace the drive belt, then go to Step
5.
NO: There is no action to be taken.
STEP 5. Retest the system.
Check the engine coolant temperature.
Q:Is the engine coolant temperature abnormally high?
YES: Return to Step 2.
NO: The procedure is complete.
14-5
ENGINE COOLING
14-6
ENGINE COOLING DIAGNOSIS
Inspection Procedure 3: Radiator Fan and Condenser Fan do not Operate
M11401000067USA0000010000
Radiator Fan and Condenser Fan Drive Circuit
FUSIBLE
LINK
BLUE − WHITE
CONDENSER
FAN RELAY
28
BLUE − WHITE
BLUE − WHITE
BLUE
BLUE
CONDENSER
FAN
MOTOR
BLACK
FAN
CONTROL
RELAY
FUSIBLE
29
LINK
RED
BLUE
RED
RADIATOR
FAN
RELAY
YELLOW − PINK
RADIATOR
FAN
MOTOR
ETACSECU
YELLOW − BLUE
BLACK
YELLOW − VIOLET
RED −
BLACK
D7G14M000A00
Fusible link (28), (29) and
connectors: A-34X, A-35X, A-36X
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
Connectors: A-05, A-43
14-7
Fusible
link (29)
Fusible
link (28)
A-34X
A-36X
A-35X
ZC603029
AA00
CIRCUIT OPERATION
｠
The cooling fan motor is energized by the fusible
link number 28 and fusible link number 29.
｠
The ETACS-ECU controls the radiator fan relay, fan
control relay, and condenser fan relay for driving the
cooling fan motor by using the input signal
transmitted from the A/C switch, engine coolant
temperature sensor, and output shaft speed sensor.
TECHNICAL DESCRIPTION
If the cooling fan does not operate, the following cases
may have occurred.
｠
Malfunction of power supply or ground circuit
｠
Malfunction of cooling fan motor
｠
Malfunction of fan control relay, radiator fan relay or
condenser fan relay
A-43
A-05
ZC603062
Connector: C-312
ETACS-ECU
C-312
｠
Malfunction of ETACS-ECU
｠
Abnormality of engine coolant temperature sensor
ZC603093
AA00
AA00
input signal transmitted to ECM
｠
Abnormality of output shaft speed sensor input
signal transmitted to TCM
｠
Abnormality of A/C switch input signal transmitted
to A/C-ECU
TROUBLESHOOTING HINTS
｠
Malfunction of fusible link
｠
Malfunction of fan control relay
｠
Malfunction of radiator fan relay
｠
Malfunction of condenser fan relay
｠
Malfunction of cooling fan motor
｠
Damaged wiring harness or connector
｠
Malfunction of ETACS-ECU
DIAGNOSIS
Required Special Tools:
｠
MB991958: Scan Tool (M.U.T.-III Sub Assembly)
｠
MB991824: V.C.I.
｠
MB991827: M.U.T.-III USB Cable
｠
MB991910: M.U.T.-III Main Harness A
｠
MB991223: Harness Set
14-8
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
｠
MB992006: Extra Fine Probe
STEP 1. M.U.T.-III other system diagnosis codes
｠
Confirm whether the diagnosis codes are output from ETACSECU (Refer to GROUP 54Ad, Diagnosis - Diagnostic
Function P.54Ad-5).
Q:Is the diagnostic trouble code output?
YES: Perform the troubleshooting of ETACS-ECU (Refer to
GROUP 54Ad, Diagnosis - Diagnostic Trouble Code Chart P.
54Ad-8).
NO: Go to Step 2.
STEP 2. Check the cooling fan relay.
Refer to P.14-17.
Q:Is the check result normal?
YES: Go to Step 3.
NO: Replace the relay.
STEP 3. Check the radiator fan relay connector A-34X,
condenser fan relay connector A-35X and fan control relay
connector A-36X.
Check for the contact with terminals.
Connector: A-34X
Relay box
side
A-34X
Q:Is the check result normal?
YES: Go to Step 4.
NO: Repair the defective connector.
STEP 4. Check the cooling fan motor.
Refer to P.14-19.
Q:Is the check result normal?
YES: Go to Step 5.
NO: Replace the cooling fan motor.
STEP 5. Check condenser fan motor connector A-43 and
radiator fan motor connector A-05.
Check for the contact with terminals.
Q:Is the check result normal?
YES: Go to Step 6.
NO: Repair the defective connector.
STEP 6. Measure the voltage at radiator fan relay connector
A-34X.
(1)
Remove the radiator fan relay, and measure at relay box
side.
(2)
Measure the voltage between terminal number 3 and ground.
Measure the voltage between terminal number 4 and ground.
OK: System voltage
Q:Is the check result normal?
YES: Go to Step 8.
NO: Go to Step 7.
ZC6036400000
Connector: A-36X
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
STEP 7. Check the harness between radiator fan relay
connector A-34X (terminal 3, 4) and fusible link number 29.
｠
Check the power supply line for short or open circuit.
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Repair the wiring harness.
STEP 8. Measure the voltage at fan control relay connector
A-36X.
(1)
Remove the fan control relay, and measure at relay box side.
(2)
Measure the voltage between terminal number 1 and ground.
OK: System voltage
14-9
Relay box
side
Connector: A-35X
Relay box
side
A-36X
ZC6036420000
A-35X
Q:Is the check result normal?
YES: Go to Step 10.
NO: Go to Step 9.
STEP 9. Check the harness between fan control relay
connector A-36X (terminal 1) and fusible link number 28.
｠
Check the power supply line for short or open circuit.
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Repair the relay box.
STEP 10. Measure the voltage at condenser fan relay
connector A-35X.
(1)
Remove the condenser fan relay, and measure at relay box
side.
(2)
Measure the voltage between terminal number 3 and ground.
Measure the voltage between terminal number 4 and ground.
OK: System voltage
Q:Is the check result normal?
YES: Go to Step 12.
NO: Go to Step 11.
ZC6036410000
STEP 11. Check the harness between condenser fan relay
connector A-35X (terminal 3, 4) and fusible link number 28.
｠
Check the power supply line for short or open circuit.
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
14-10
Connector: A-36X
Relay box
side
A-36X
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Repair the relay box.
STEP 12. Check the harness between radiator fan relay
connector A-34X (terminal 2) and radiator fan motor
connector A-05 (terminal 1).
｠
Check the output line for short or open circuit.
Q:Is the check result normal?
YES: Go to Step 13.
NO: Repair the wiring harness.
STEP 13. Check the harness between fan control relay
connector A-36X (terminal 2) and radiator fan motor
connector A-05 (terminal 2).
｠
Check the output line for short or open circuit.
Q:Is the check result normal?
YES: Go to Step 14.
NO: Repair the wiring harness.
STEP 14. Check for continuity at fan control relay connector
A-36X.
(1)
Remove the fan control relay, and measure at relay box side.
(2)
Check that there is continuity between terminal number 5 and
body ground.
OK: Continuity (less than 2 ohms)
Q:Is the check result normal?
YES: Go to Step 16.
NO: Go to Step 15.
ZC6036420000
STEP 15. Check the harness between fan control relay
connector A-36X (terminal 5) and ground.
｠
Check the ground line for open circuit.
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Repair the wiring harness.
STEP 16. Check the harness between fan control relay
connector A-36X (terminal 4) and condenser fan relay
connector A-35X (terminal 2).
｠
Check the output line for short or open circuit.
Q:Is the check result normal?
YES: Go to Step 17.
NO: Repair the wiring harness.
A-43 Harness
connector:
Component side
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
STEP 17. Check the harness between condenser fan relay
connector A-35X (terminal 2) and condenser fan motor
connector A-43 (terminal 1).
｠
Check the output line for short or open circuit.
Q:Is the check result normal?
YES: Go to Step 18.
NO: Repair the wiring harness.
STEP 18. Check for continuity at condenser fan motor
connector A-43.
(1)
Remove the condenser fan motor connector, and measure
at harness side.
(2)
Check that there is continuity between terminal number 2 and
body ground.
OK: Continuity (less than 2 ohms)
Q:Is the check result normal?
YES: Go to Step 20.
NO: Go to Step 19.
14-11
ZC6036480000
STEP 19. Check the harness between condenser fan motor
connector A-43 (terminal 2) and ground.
｠
Check the ground line for open circuit.
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Repair the wiring harness.
STEP 20. Check the harness between ETACS-ECU
connector C-312 (terminal 2) and radiator fan relay
connector A-34X (terminal 1).
｠
Check the ETACS-ECU input line for open circuit.
Q:Is the check result normal?
YES: Go to Step 21.
NO: Repair the wiring harness.
STEP 21. Check the harness between ETACS-ECU
connector C-312 (terminal 9) and fan control relay
connector A-36X (terminal 3).
｠
Check the ETACS-ECU input line for open circuit.
Q:Is the check result normal?
YES: Go to Step 22.
NO: Repair the wiring harness.
STEP 22. Check the harness between ETACS-ECU
connector C-312 (terminal 8) and condenser fan relay
connector A-35X (terminal 1).
｠
Check the ETACS-ECU input line for open circuit.
14-12
ENGINE COOLING
ENGINE COOLING DIAGNOSIS
Q:Is the check result normal?
YES: Go to Step 23.
NO: Repair the wiring harness.
STEP 23. M.U.T.-III actuator test
Conduct the MFI system actuator test to check that the fan
works. (Refer to GROUP 13Ab, Actuator Test Reference
Table P.13Ab-857).
｠
Item 14: Cooling fan
Q:Is the check result normal?
YES: An intermittent malfunction is suspected (Refer to
GROUP 00, How to Use Troubleshooting/Inspection Service
Points - How to Cope with Intermittent Malfunctions P.
00-15).
NO: Replace the ETACS-ECU (Refer to GROUP 54Ad, ETACS-
ECU P.54Ad-93). Then go to Step 24.
STEP 24. Retest the system.
Check that the radiator fan and the condenser fan work.
Q:Is the check result normal?
YES: The procedure is complete.
NO: Return to Step 1.
ENGINE COOLING
SPECIAL TOOLS
SPECIAL TOOLS
Tool Tool number and name Supersession Application
A
MB991824
B
C
D
Do not use
E
Do not use
F
MB991827
MB991910
MB991911
MB991914
MB991958
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991914
F: MB991825
G: MB991826
M.U.T.-III sub assembly
A: Vehicle
communication
interface (V.C.I.)
B: M.U.T.-III USB cable
C: M.U.T.-III main
harness A (Vehicles
with CAN
communication system)
D: M.U.T.-III main
harness B (Vehicles
without CAN
communication system)
E: M.U.T.-III main
harness C (for Daimler
Chrysler models only)
F: M.U.T.-III adapter
harness
G: M.U.T.-III trigger
harness
MB991824-KIT
NOTE: G: MB991826
M.U.T.-III trigger
harness is not
necessary when
pushing V.C.I. ENTER
key.
For vehicles with CAN
communication, use
M.U.T.-III main harness A
to send simulated vehicle
speed. If you connect
M.U.T.-III main harness B
or C instead, the CAN
communication does not
function correctly.
Reading diagnostic trouble
codes
14-13
M11401000006USA0000010000
MB991825
G
MB991826
YB9919580001
ENGINE COOLING
14-14
SPECIAL TOOLS
Tool Tool number and name Supersession Application
A
MB991223
A: MB991219
B: MB991220
General service tools Checking the continuity and
measuring the voltage at the
harness connector
C: MB991221
D: MB991222
B
Harness set
A: Test harness
B: LED harness
C: LED harness
C
adaptor
D: Probe
D
Do not use
YB9912230001
MB992006
YB992006AA01
YB991871AA01
YB992042AA00
MB992006
Extra fine probe
MB991871
LLC changer
MB992042
Engine coolant
temperature sensor
wrench
MD998412
Guide
General service tool Continuity check and
voltage measurement at
harness wire or connector
for loose, corroded or
damaged terminals, or
terminals pushed back in the
connector.
General service tool Coolant refilling
- Engine coolant temperature
sensor removal and
installation
- Thermostat housing and
gasket installation
YD998412AA00
ENGINE COOLING
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
14-15
M11401000010USA0000010000
Cap adapter
Adapter
ZC602733
Cap adapter
ZC602734
AA00
AA00
When pressure testing the cooling system, slowly release
cooling system pressure to avoid getting burned by hot
coolant.
｠
Be sure to completely clean away any moisture from the
places checked.
｠
When the tester is taken out, be careful not to spill any
coolant.
｠
Be careful when installing and removing the tester and
when testing not to deform the filler neck of the radiator.
1.
Check that the coolant level is up to the filler neck. Install a
radiator tester and apply 160 kPa (23 psi) pressure, and then
check for leakage from the radiator hose or connections.
2.
If there is leakage, repair or replace the appropriate part.
RADIATOR CAP PRESSURE CHECK
M11401000013USA0000010000
NOTE: Be sure that the cap is clean before testing. Rust
or other foreign material on the cap seal will cause an
improper reading.
1.
Use a cap adapter to attach the cap to the tester.
2.
Increase the pressure until the indicator of the gauge stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93 - 123 kPa (14 - 18 psi)
3.
Replace the radiator cap if the reading does not remain at or
above the limit.
ENGINE COOLANT REPLACEMENT
M11401000012USA0000010000
Required Special Tool:
｠
MB991871: LLC Changer
When removing the radiator cap, use care to avoid contact
with hot coolant or steam. Place a shop towel over the cap
and turn the cap counterclockwise a little to let the pressure
escape through the vinyl tube. After relieving the steam
pressure, remove the cap by slowly turning it
counterclockwise.
14-16
Front roll stopper
Air hose
Water feed
hose B
ZC602730
MB991871
ZC602532
AA00
AA00
ENGINE COOLING
ON-VEHICLE SERVICE
1.
Drain the water from the radiator, heater core and engine after
unplugging the radiator drain plug and removing the radiator
cap.
2.
Remove the water feed hose B, and drain the coolant in the
water jacket.
3.
Remove the radiator condenser tank assembly and drain the
coolant.
4.
Drain the coolant then clean the path of the coolant by injecting
water into the radiator from the radiator cap area.
5.
Install the water feed hose B.
6.
Securely tighten the radiator drain plug.
7.
Assemble the radiator condenser tank assembly.
｠
Do not use alcohol or methanol anti-freeze or any engine
coolants mixed with alcohol or methanol anti-freeze. The
use of an improper anti-freeze can cause corrosion of the
aluminum components.
｠
If the coolant contact the PremAir® direct ozone
reduction (DOR) radiator, wash it with water at once.
Vehicles for California emission regulation
8.
By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the range
of 30 to 60 %. Use special tool MB991871 to refill the coolant.
A convenient mixture is a 50 % water and 50 % antifreeze
solution [freezing point: -31°C (-24 °F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Quantity:
9.5 dm3(10.0 quarts)
10.0 dm3(10.6 quarts) <Vehicles with Towing
Package or DOR radiator>
9.
Reinstall the radiator cap.
10.
Start the engine and let it warm up until the thermostat opens.
11.
After repeatedly revving the engine up to 3,000 r/min several
times, stop the engine.
12.
Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
Do not overfill the radiator condenser tank assembly.
13.
Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
ENGINE COOLANT CONCENTRATION TEST
M11401000011USA0000010000
Refer to GROUP 00, Recommended Lubricants And Lubricant
Capacities Table P.00-51.
2
1 3
4
5
Fan control relay
2
1
ZC601035
4
5
3
ENGINE COOLING
ON-VEHICLE SERVICE
14-17
COOLING FAN RELAY CONTINUITY CHECK
M11401000062USA0000010000
FAN CONTROL RELAY CONTINUITY CHECK
Battery
voltage
Not applied 2 - 4 Continuity (less than 2
Not applied 2 - 5 Open circuit
Connect
terminal No.3
and battery (-)
terminal.
Connect
terminal No.1
and battery (+)
terminal.
Terminal No. to be
connected to tester
Continuity test
results
ohms)
Continuity (less than 2
ohms)
ZC602833
AA00
14-18
Radiator fan relay
ZC601035
ENGINE COOLING
ON-VEHICLE SERVICE
RADIATOR FAN RELAY CONTINUITY CHECK
Battery
voltage
Terminal No. to be
connected to tester
Continuity test
results
Not applied 4 - 2 Open circuit
Connect
terminal No.3
4 - 2 Continuity (less than 2
ohms)
and battery (+)
terminal.
Connect
terminal No.1
and battery (-)
terminal.
2
1 3
4
4
3
Condenser fan relay
2
1
ZC602834
ZC601035
AA00
CONDENSER FAN RELAY CONTINUITY CHECK
Battery
voltage
Terminal No. to be
connected to tester
Continuity test
results
Not applied 4 - 2 Open circuit
Connect
terminal No.3
4 - 2 Continuity (less than 2
ohms)
and battery (+)
terminal.
Connect
terminal No.1
and battery (-)
terminal.
2
1 3
4
4
2
3
1
ZC602835
AA00
Rariator fan motor
ENGINE COOLING
ON-VEHICLE SERVICE
COOLING FAN MOTOR CHECK
M11401000019USA0000010000
1.
Disconnect the fan motor connector.
2.
Check that the fan motor runs when a positive battery terminal
is connected to the fan motor-side connector terminal number
1, and terminal number 2 is grounded. Also check to see that
there is no abnormal sound emitted from the fan motor at this
time.
3.
If the fan motor is defective, replace it (Refer to P.14-27).
14-19
ZC602533
Condenser fan
motor
ZC602534
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Coolant Draining and Refilling (Refer to P.14-15).
｠
Air Cleaner Removal and Installation (Refer to GROUP 15, Air Cleaner P.15-6).
｠
Battery and Battery Tray Removal and Installation
｠
AA00
AA00
THERMOSTAT
M11401000024USA0000010000
14-20
ENGINE COOLING
THERMOSTAT
3
<<A>> >>B<< 1. Radiator lower hose connection
Removal steps
2. Water inlet fitting
REMOVAL SERVICE POINT
<<A>> RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
Mating marks
2
1
Removal steps
>>A<< 3. Thermostat
23 ± 6 N·m
17 ± 4 ft-lb
ZC600494
AA00
ZC6006480000
Rubber ring
Jiggle valve
ZC5015940000
ENGINE COOLING
THERMOSTAT
14-21
INSTALLATION SERVICE POINTS
>>A<< THERMOSTAT INSTALLATION
Make absolutely sure that no oil adheres to the rubber ring
of the thermostat. Also do not fold or scratch the rubber ring
during installation.
Install the thermostat so that the jiggle valve is facing straight up.
Be careful not to fold or scratch the rubber ring.
Projection
Water inlet fitting
Mating marks
ZC6006490000
>>B<< RADIATOR LOWER HOSE INSTALLATION
1.
Insert each hose as far as the projection of the water inlet
fitting.
2.
Align the mating marks on the radiator hose and hose clamp,
and then connect the radiator hose.
INSPECTION
M11401000025USA0000010000
Thermostat Check
1.
Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value: Valve opening temperature: 82 ± 1.5°
C (180 ± 3°F)
ZC600851AA00
ENGINE COOLING
14-22
WATER PUMP
2.
Check that the amount of valve lift is at the standard value
when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is
fully closed, and use this measurement to compare the
valve height when the thermostat is fully open.
Standard value:
Valve lift
ZC6008520000
Full-opening temperature: 95°C (203°F)
Amount of valve lift: 9.0 mm (0.35 inch)
WATER PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Coolant Draining and Refilling (Refer to P.14-15).
｠
Timing Belt Removal and Installation (Refer to GROUP 11A, Timing Belt P.11A-49).
｠
M11401000027USA0000010000
N
2
23 ± 6 N·m
17 ± 4 ft-lb
1
Removal steps
1. Water pump
Removal steps
2. Water pump gasket
ZC600496
AA00
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Thermostat Removal and Installation (Refer to P.14-19).
｠
N
22
21
N
22
N
19
ENGINE COOLING
WATER HOSE AND WATER PIPE
WATER HOSE AND WATER PIPE
20 ± 5 N·m
N
15 ± 3 ft-lb
9
7
30 ± 9 N·m
22 ± 7 ft-lb
11
N
8
17
4
10
5.0 ± 1.0 N·m
44 ± 9 in-lb
16
11 ± 1 N·m
98 ± 8 in-lb
N
20
12
23 ± 6 N·m
17 ± 4 ft-lb
M11401000033USA0000010000
23 ± 3 N·m
13
17 ± 2 ft-lb
14
14
14-23
1
Removal steps
<<A>> >>D<< 1. Radiator upper hose connection
2. EGR valve connector
3. Water hose
4. Water hose
5. EGR valve
6. EGR valve gasket
7. EGR pipe
8. EGR pipe gasket
9. EGR pipe gasket
23 ± 6 N·m
17 ± 4 ft-lb
<<B>> >>C<< 11. Engine coolant temperature sensor
18
N
2
5
15
23 ± 6 N·m
17 ± 4 ft-lb
6
3
ZC600577
Removal steps
10. Engine coolant temperature sensor
connector
12. Water hose
13. Water hose
14. Heater hose connection
15. Water return hose and pipe assembly
connection
16. Harness bracket
AA00
14-24
ENGINE COOLING
WATER HOSE AND WATER PIPE
Removal steps
Oil pipe clamp bolt (Refer to GROUP
·
11A, Cylinder Head Gasket P.
11A-45).
17. Water hose
<<C>> >>B<< 18. Thermostat housing
Required Special Tools:
｠
MB992042: Engine Coolant Temperature Sensor
Wrench
REMOVAL SERVICE POINTS
<<A>> RADIATOR UPPER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
>>B<< 19. Gasket
>>B<< 20. Gasket
>>A<< 22. O-ring
｠
MD998412: Guide
Removal steps
21. Water inlet pipe
MB992042
Mating marks
ZC6006480000
<<B>> ENGINE COOLANT TEMPERATURE SENSOR
REMOVAL
Use special tool MB992042 to remove the engine coolant
temperature sensor.
ZC5017160000
O-ring
Control wiring
harness
ZC6020910000
ENGINE COOLING
WATER HOSE AND WATER PIPE
<<C>> THERMOSTAT HOUSING REMOVAL
Remove the two control wiring harness clamps, and remove the
thermostat housing.
INSTALLATION SERVICE POINTS
>>A<< O-RING INSTALLATION
Do not allow engine oil or other grease to adhere to the Oring
Insert the O-ring to the water inlet pipe, and coat the outer portion
of the O-ring with water or engine coolant.
14-25
Thermostat housing
or bank stiffener
Water inlet pipe
Cylinder head
Thermostat housing
ZC5002530000
MD998412
Gasket
ZC601879
>>B<< GASKET/THERMOSTAT HOUSING INSTALLATION
Using the special tool MD998412, install the thermostat housing
while supporting the gasket.
AA00
14-26
MB992042
ZC500254AA00
AC103399
ENGINE COOLING
WATER HOSE AND WATER PIPE
>>C<< ENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
1.
Apply the specified sealant to the thread of the engine coolant
temperature sensor.
Specified Sealant: 3M™ AAD Part No. 8731 or
equivalent
2.
Use special tool MB992042 to install the engine coolant
temperature sensor.
Projection
Thermostat housing
ZC5017160000
Mating marks
ZC6006490002
>>D<< RADIATOR UPPER HOSE INSTALLATION
1.
Insert each hose as far as the projection of the thermostat
housing.
2.
Align the mating marks on the radiator hose and hose clamp,
and then connect the radiator hose.
INSPECTION
M11401000034USA0000010000
Water Pipe and Hose Check
Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.
ENGINE COOLING
REMOVAL AND INSTALLATION
Vehicles for California emission regulation
｠
Never remove the radiator sensor from the
radiator because it cannot be disassembled.
When replacing the radiator sensor, replace it
with the radiator as a set. When the radiator
Pre-removal Operation
Engine Coolant Draining (Refer to P.14-15).
｠
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.
｠
15-6).
RADIATOR
RADIATOR
M11401000015USA0000010000
sensor is removed from the radiator, the engine
control module (ECM) detects an error and sets
a diagnostic trouble code.
｠
Never replace the DOR radiator with the NONDOR radiator.
｠
Never clean the DOR radiator with a high
concentration of alkaline cleaner.
Post-installation Operation
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner P.
｠
15-6).
Engine Coolant Refilling and Level Check (Refer to P.14-15).
｠
Transmission Fluid Refilling and Level Check (Refer to GROUP
｠
00, Maintenance Service - Transmission Fluid P.00-64).
14-27
14-28
ENGINE COOLING
RADIATOR
9.0 ± 2.0 N·m
80 ± 17 in-lb
9.0 ± 2.0 N·m
80 ± 17 in-lb
4
24 ± 4 N·m
18 ± 3 ft-lb
9.0 ± 2.0 N·m
16
3
6
12 ± 2 N·m
102 ± 22 in-lb
7
12
8
18
17
80 ± 17 in-lb
5
1
20
18
12 ± 2 N·m
102 ± 22 in-lb
5.0 ± 1.0 N·m
44 ± 9 in-lb
21
N
2
25
15
19
26
4.0 ± 2.0 N·m
36 ± 17 in-lb
19
10
9
12 ± 2 N·m
102 ± 22 in-lb
23
Radiator removal steps
1. Drain plug
2. O-ring
3. Radiator cap
4. Transmission oil cooler line hose and
tube assembly
5. Radiator condenser tank hose
<<A>> >>A<< 6. Radiator upper hose
7. Radiator cap assembly
<<A>> >>A<< 8. Radiator upper hose
9. Clamp
<<A>> >>A<< 10. Radiator lower hose
11
ZC600426
24
AA00
14
22
Radiator removal steps
11. Radiator hose support
12. Radiator sensor connector <DOR
radiator>
13. Radiator fan motor connector
14. Condenser fan motor connector
15. Fan, fan motor and cooling fan shroud
assembly
Radiator grille, headlight support upper
·
panel cover (Refer to GROUP 51A,
Radiator Grille P.51A-7).
13
ENGINE COOLING
RADIATOR
14-29
Radiator removal steps
Front impact sensor (Refer to GROUP
·
52B, Front Impact Sensor P.
52B-324).
Hood lock release cable, hood latch
·
(Refer to GROUP 42Aa, Hood P.
42Aa-5).
16. Front end upper bar assembly
17. Radiator assembly
18. Support upper insulator
19. Support lower insulator
20. Radiator condenser tank
21. Radiator condenser tank bracket
Cooling fan shroud removal steps
5. Radiator condenser tank hose
REMOVAL SERVICE POINT
<<A>> RADIATOR UPPER HOSE/RADIATOR LOWER HOSE
DISCONNECTION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
Cooling fan shroud removal steps
<<A>> >>A<< 6. Radiator upper hose
7. Radiator cap assembly
12. Radiator sensor connector <DOR
radiator>
13. Radiator fan motor connector
14. Condenser fan motor connector
15. Fan, fan motor and cooling fan shroud
assembly
22. Radiator fan motor
23. Fan
24. Condenser fan motor
25. Fan
26. Cooling fan shroud
Projection
Water inlet fitting,
thermostat housing
or radiator
Mating marks
ZC6006480000
Mating marks
ZC6006490001
INSTALLATION SERVICE POINT
>>A<< RADIATOR LOWER HOSE/RADIATOR UPPER HOSE
INSTALLATION
1.
Insert each hose as far as the projection of the water inlet
fitting, thermostat housing or radiator.
2.
Align the mating marks on the radiator hose and hose clamp,
and then connect the radiator hose.
14-30
MEMO
ENGINE COOLING
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