ENGINE COOLING 6¢~1 6C. ENGINE COOLING ; GENERAL DESCRIPTION The cooling system mainiains engine temper- ature at an efficient level during all engine operating conditions. When the engine is cold the system cools slowly or not at all to allow the engine to warm up quickly ‘The cooling system includes a radiator and y sub-system, cooling fan, thermostat and water pump, and drive belt Opzration of the Cooling system requires proper functioning of all components. Coolant is draw from the radiator by the water pump and circulated through water jackets in the engine block, the intake manifold, the cylinder head, and then routed back to the radiator where it cools. This system directs some coolant through hoses to the heater core, to provide for heating and Diictrosting. A reservoir tank is connected to the radiator {0 recover coolant displaced by expansion from high temperatures and maintain correct coo- lant level, As the cookant cools and contracts it is drawn buck inte the radiator by vacuum, The cooling system for this vehicle has no radiator cap or filler neck, Coolant ts added to the reservoir tank RADIATOR A cross-flow radiator is used on all models. ‘Tanks in this type radiator are located to the sight and left of the core, instead of above and below Radiators used with automatic transmission have oil coolers with inlet and outlet fittings for transmission fluid circulation. Cars with maaual transmissions use radiators without oi coolers. Vehicles equipped with air conditioning may use ph reilonseticent cline al RADIATOR RESERVOIR TANK A “see-through” plastic reservoir, similar to the familiar windshield washer jar. is connected to the radiator by hose. As the vehicle ts driven the coolant is heated and expands. The portion Of the Muid displaced hy this espansion flows trom the radiator into the Teservoit tank. When the engine is Stopped. and the coolant cools and con ed coolint is drawn back into the radiator is kept jets, the displ the radiator by vacuum, Thu: filled with coolant to the desired level at all times. resulting in increased cooling efficiency. Coolant level stould be at or above the appropriate mark oon the reservoir tank when the systems is cold ELECTRIC FAN Fan size is 366mm with 5 blades to aid air flow through the radiatorjcondenser, The fan is driven by an eiectrie motor which is attached to the rad- iator support. The fan motor is activated by a coolant tempera ture switch. If the vehicle is equlpped with A/C, a second switch can activate the circuit, depending upon A/C compressor head pressure to the con- denser. CAUTION ; Ifa fan blade is bent or damaged in any way, no attempt should be made to repair and reuse the damaged part. A bent or damaged fan assembly should always be replaced with anew fan assembly. It is essential that fan assemblies remain in proper balance and proper balance cannot be assured once a fan assembly has boen bent or damaged. A fan assemb not in proper balance could fail and fly apart during subsequent use, creating: aan extremely dangerous condition A fan shroud is used to direct air towards the engine and to allow minimal recirculation of sir around the fan TEMPERATURE SWITCH This switeh activates a warning lamp in the instrument cluster if the engine overheats. With optional instrumentation, a temperature gage rep- laces the warning lamp and the temperature switch 5 replaced with a transducer COOLANT TEMPERATURE FAN SWITCH This switch regulates soltay fan relay, which operates the fun whevever the engine coolant temperature exceeds [10> THERMOSTAT A Thermostat is used in the cookin passage to control the flow of engine coolant, to provide fast engine warm-up and to regulate coolant temperatures. The thermostat remains elosed while the cooant is cold, preventing circulation of cvokant through the radiator. At this point lowed to cireulate only throughout to warm it quickly and evenly As the engine warms. the thermostat opens, permitting cookint i flow through the radiator is dissipated through radiator walls to the coolant soolant is, he engine8~2 ENGINE COOLING This opening and closing of the thermostat permits enough coolant to enter the radiator to keep the engine within operatiag limits. COOLANT RECOVERY SYSTEM ‘A recovery-type cooling system is standard on all vehicles an is designed to maintain the engine at the proper operating temperature. The reservoir tank collects coolant that expands with ing temperature and would otherwise overflow from the system. When the system temperature drops, the coolant is drawn from the reservoir tank back into the radiator by the suction created by coolant contraction, The cooling system has been filled at the factory with a high-quality, rust inh- ibiting, year-around coolant “This coolant solution provides freezing prot. ection to at least-37, It has been formulsted to be used for two full calendar years with normal operation provided the proper mixture of coolant to water is maintained. DIAGNOSIS CHART The diagnostic charts in this section cover common problems and possible causes. When the proper diagnosis is made, the problem should be eoriected by part replacement, adjustment, of repair as required. Refer to Figures | through 4 for the appropriate diagnosis chart SERVICE PROCEDURES COOLING SYSTEM CARE Check the coolant level visually ia the “se through” reservoir tank every time the hood is up. ‘At normal operating temperature the coolant level should increase. Coolant should be added only to the resetvoir tank to raise level to the appropriate mark. use a 50/50 mixture of high-quality ethylene alycol antifreeze and water for cookint additions, NOTICE: If recommended quility antifreere is used, supplemental inhibitors or additives claim to provide the increased cooling capability are not hecessary, They may be detriniental to the efficient operation of the system, and represent an unnec: essary operating expense Fyery 12 months, the cooling system should be serviced as follows 1, Wash reservoir tank cap with clan water, 2! Check coolant for proper level and freeze pro: tection, 3. Pressufe test system and reservoir sank cap for proper pressure holding capacity. 103 kPa (15 psi). If replacement of cap is required, use the proper cap specified for vehicle model 4. Tighten hose clamps and inspect all hoses Replace hoses whenever cracked, swollen or otherwise deteriorated. 5, Clean front area of radiator core and air cond- itioning condenser DRAINING AND REFILLING THE COOLING SYSTEM {2 Important «Dispose of used coolant in a proper fashion, ie, in a used coolant hoding twnk which is picked up along with used oil. NEVER POUR USED COOLANT DOWN THE DRAIN! Ethylene glycol antifreeze is a very toxic chem: ical : disposing of it into the sewer system or ground water is both illegal and ecologically unsound! Replace hoses every 24 months or earlier if cracked, swollen or otherwise deteriorated, ‘Also, al that time, drain and refill the cooling system using the following recommended procedure 1. Remove reservoir tank pressure cap. CAUTION : To avoid being burned, do not remove reservoir tank cap while engine and radiator are stil hot, Scalding fluid and steam may be blown out under pressure Remove radiator and wash out thoroughly Remove reservoir tank(sce On-Vehicle Service), Install radiator and reservoir tank. | Reconnect all hoses, except radiator top hose. Refill cooling system(see On-Vehicle Service. radiator procedure) Tighten top radiator hose 8. Ran engine until thermostat opens © important © Block the drive wheels, place transmission in PAPK (automatic transmission), or NEUTRAL {manual transmission) and engage the parking, brake 9, After system hits edoled, top off reservoir tank coolant level CAUTION : Under seme conditions, the ethylene glycol in engine coolant is flammable. To help Avoid being burned when adding coolant. Do NOT spill it on the exhaust system oF hot engine parts. Keep the fresze protection at t level appropriate o the temperatures which may occur in the area of vehicle operation 1. Maintain cooling syste fivege protection at 37, to ensure protection against corrosion and loss of coolant from boiling, even though freczing temperatures are not expectedENGINE COOLING & -ENGINE COOLING SYSTEM COMPLAINT To AVOID NEEDLESS TIME AND COST IN DIAGNOSING COOLING SYSTEM COMPLAINTS, THE CUSTOMER SHOULD BE QUESTIONED ABOUT DRVING CONDITIONS THAT PLACE ABNORMAL LOADS ON THE COOLING system 1.DOES OVERHEATING OCCUR WHILE PULLING A TRAILER? IF ANSWER IS “YES"—HOW HEAVY IS TRAILER? IF TRAILER WEIGHT IS GREATER THAN é50ixs & CAR 15 EQUIPPED WITH NORMAL DUTY COOLING SYSTEM, A HEAVY DUTY COOUNG PACKAGE IS REQUIRED (PER MFR'S TRAILER HAULING SPECS). FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED. 2.15 CAR EQUIPPED WITH ADD-ON O8 AFTER MARKET AIR CONDITIONING SYSTEM? IF ANSWER IS “YES” —WAS HEAVY DUTY RADIATOR INSTALLED WITH THE SYSTEM? IF NOT, INSTALL HEAVY DUTY AIR CONDITIONNG RADIATOR FOR THE CAR MODEL INVOLVED (PER MANUFACTURER'S SPECS). FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQURED. 3.15 OVERHEATING OCCURRING AFTER PROLONGED IDLE, IN GEAR, A / C SYSTEM OPERATING? IF ANSWER IS "YES" INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVOID OVERHERTING SUCH AS 2. IDLE IN NEUTRAL AS MUCH AS POSSIBLE INCI FLOW THROUGH RADIATOR. b. TURN A/ SYSTEM OFF DURING EXTENDED IDLES IF OVERHEATING IS INDICATED BY HOT LIGHT OR TEMP. GAGE. FURTHER DIAGNOSTIC CHECKS SHOULD NOT B= REQUIRED. 4.15 OVERHEATING OCCURRING AFTER PROLONGED ORIVING IN SLOW CITY TRAFFIC, TRAFFIC MMS, GARAGES, ect IF ANSWER IS “YES"-INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVOID OVERHEATING SAME AS FOR PROLONGED IDLES —NO. 3 FURTHER DISGNOSTIC CHECKS SHOULD NOT BE REQUIRED. \SE ENGINE R.P.M. TO GET HIGHER AIR FLOW & WATER _IF NONE OF THE ABOVE APPLY, GO TO DIAGNOSTIC CHART TO EFFECTIVELY USE THS CHART, QUESTION THE OWNER TO DETERMINE WHICH OF THE FOLLOWING (3) CATEGORIES APPLIES TO THE COMPLANT : |, HOT LIGHT OR HOT INDICATION ON TEMPERATURE GAGE 2.BOIING: 3. COOLANT LOSS, 1.(F COMPLAINT IS HOT LIGHT OR HOT INDICATION ON TEMPERATURE GAGE WAS HOT LIGHT ACCOMPANIED By BOILING? IF ANSWER IS “YES”, GO TO BOILING ON CHART IF ANSWER IS *NO", GO TO HOT LIGHT ON CHART 2. F COMPLAINT IS BOILING~GO TO BOILING ON CHART IF PFOBLEM REMAINS, GO TO COOLING FAN DIAGNOSIS, 3. F COMPLAINT IS COOLANT LOSS DETERMINE IF CUSTOMER IS OVERFILLING THE SYSTEN, THIS WOULD NORMALLY RESULT IN SMALL AMO UNTS OF COOLANT LOSS THROUGH THE OVERFLOW TUBE. IF THIS IS THE CASE, INSTRUCT THE CUSTOMER ON PROPER FILL LEVEL & NO FURTHER DIAGNOSTIC CHECKS SHOULD BE REQUIRED. IF OVERFILLING 1S NOT THE PROBLEM, GO TO COOLANT LOSS ON CHART. NOTICE» ANYTIME COOLING SYSTEM IS OBVIOUSLY CONTAMINATED, THE SYSTEM SHOULD Be DRAINED AND FLUSHED. CAUTION : THE COOLING SYSTEM IS DESIGNED TO OPERAIE AI 1S P.SI. PRESSURE & TEMPERATURES EXCEEDING 93°. CAUTION SHOULD BE FXFRCISED WHEN REMOVING FRESSURE CAP OR SER. VICING THE SYSTEM, "Fig. 1 Cooing System Diagnosis Chart( | of 3)60-4 ENGINE COOLING. BOILING/ENGINE OVERHEAT/ENGINE COOLANT LOSS RR TET Or % RETESET sana wake Taras aS x }——— Trae RerToRTSE ETS fc 1 ae, oe TTGHTEN 10 SPEC. collapsed yes, REMOVE OBSTRUCTION ok (Of REPLACE FAN = = to (CHECK COOUINT LEVEL _j-————ef "vist SYSTEM CHECK pox ‘CHECK PRESSURE CAF, TEARS — Cheek Poses, rad abr, clamps, water pune, termostat housing. rad. dain, soft plugs, heate ‘water valve, heater core FOAMING COOLANT ~ Opsens in flier neck atte feneine warmuo ‘OVERFLOW SYS) ad TePIACE SS 700) FREEZE PROTECTION pow CHECK BULB os - eee Ly beennar canon AChack gasket in pressure peniace COOLANT TEN, GAUGE. eo tr ta ok, ‘carmos, overtow ote. fillerneck apele check for obstructions hose between radiator notte REPAIR OR REPLACE DEFECTS TECH SENDING UNIT REPIACE, SYSTEM OK bad PERFORM ON-CAR THERMO STAT CHECK SYSTEM OK. ‘CHECK ELECTRIC COOLING FAN EQUIPPED —_— PRESSURE CHIGR SYSTE REPLACE RELAY, FAN, 8 FAN switch? Hare reuse rnoipae _ TFs we Jos fre Seman iz | [eae — vars | Lt | feautee epee tre orem ‘state me oanay rata arstewt | aac 3 se eens Ok necked in tie der [gta es Fig. 2 Cooling System Diagnosis Chan(2 of 3)ENGINE COOLING 6¢ A. PROBLEMS NOT REQUIRING DISASSEMBLY OF COOLING SYSTEM |- LARGE OaSTAUCTIONS BLOCKING RADIATOR Om CONDENSER 4 JOXILARY OIL COOLERS. b-ucense pares] mien c. SPARE TIRES 4. CE, MUD 02 SNOW OBSTRUCTING GRLLE -REMOVE 2 ENOINE ell OYERTILL— CHECK ENGINE OL DFSTICK 3. WRONG RADIATOR FOR APPLICATION— CHECK PART NO. AGAINST PARTS LiST 4 LOOSE, DAMAGE OR MISSING AIR SEALS SEE BOOY SERVICE MANUAL '5 MISSING OR DAMAGED LOWER AIA BAFFLE ~ GEE BODY SERVICE MANUAL 5 WRONG IGNITION TIMING~SEE CHASSIS SERUCE MANUAL B. PROBLEMS REQUIRING DISASSEMBLY OF COOLING SYSTEM |. INCORRECT OR DAMAGED FAN-CHECK PART NO. AGAINST PARIS LIST 2. PHESSURE CHECK COOLING SYSTEM WITH PRESSURE CAP INSTALLED WILL SHOW IF PRESSURE CaP LUEAHS BECAUSE OF RADIATOR FILLER NECK DAMAGE 3. DEFECTIV: WATER PUMP |, ERODED OF BROKEN IMPELLER VANES », FAILED BEATING OR SEAL~ CHECK FOR SHAFT OW BEARING PLAY 4, PLUGGED RADIATOR TUBES ~SEND TO RADIATOR REPAIH SHOP FOR FLOW CHECK 5: INTERNAL SYSTEM LEAKS a HEAD GASKET 1. CRACKED BLOCK. ©, TIMING BELT coveR 4. INTAKE MANIFOLD GASKET 5. PLUGGED COOLANT PASSAGES IN CYLINDER HEROS - REMOVE HEADS AND CHECK USUALLY Fig. 3 Cooling System Diagnosis Chart(3 of 3) ENGINE OVERHEAT BOILING — POOR ENGINE COOLING |. RELEVE PRESSURE AND CAREFULLY RENOVE AADIATOR CAP. 2, RUB ST» TEMPERATURE STICK ONTO THERMOSTAT HOUSING. 3. WARM UP ENGINE AT FAST IDLE WATCH FOR COOLANT FLOW BEFORE MARK BEGINS TO MELT NO COOLANT FLOW: INSTALL NEW y “NOTE : THE TEMPERATURE STICK IS A PENOI LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING IAN CHEMICALS WHH MELT AT A GVENTe¥PeRAnETaveERATURE Srcks om ae aro To neremane \S* { THCRMOSTATS OFERATION TEMPERATURE BY RUBBING BTA D ENGINE—SLOW WARMUP—NOT ENOUGH HEAT |, RELIEVE FRESSURE AND CAREFULLY RENOVE RADIATOR CAP, 2. RUB 87 (+ TEMPERATURE STICK ONTO THERMOSTAT HOUSING, 3. WARY UP ENGNE AT FAST IDLE VAICH FOR Ci IeRVOSTAT T {COLA FLOW PROBLEM Ty CAUSED By (OTHER THAN BAD THERMOSTAT. IOLANT FLOM! BEFORE MARK BEGINS 10 MELT, _ t — COOLANT FLOW ———t esa paw aan CISD SRA sta \ TO 8 SURE) - STICKS OW THE THEAMUSTAT HOL a ‘SING, THE MARKS NADE BY THE STICHS SHOULD WELT WHEN COD-ANI TENPERATURES OF 87° AND 97 ARE REACHLD, HESPECTIELY, THESE TEMPERATURES 8 THEREFORE, I THE COGLANT FLOWS 45 INDICATED 6 a Der ™ THE NORMAL OPERATING RAGL OF THE THERMOS NOSIS CHART, THE THERMOSTAT MAY Fig. 4 Thermostat Diagnosis Chart60-6 ENGINE COOUNG. b. Add ethylene glycol base coolant when coolant additions are required because of coolant loss, or 0 provide additional protection against freezing at temperatures lower than-37°C. NOTICE: Alcohol or methanol base coolants or plain water, ure not recommended at any time. ALUMINUM RADIATOR REPAIR This radiator utilize an aluminum core with plastic side tanks. The core and side tanks con be replaced separately and core repair is easily made with the hot melt adhesive method. A transmission cil cooler may be located in one of the side tanks. ‘The oil cooler can be replaced. CORE The core is made of aluminum and is of the crossflow design. It utilizes large tubes that resist plugging, and repairs to the tubes and core are easily made using the hot melt adhesive method, The core is attuched to the tanks by clinched tabs on the core that can be bent back if tank or core rephicement is required. If the damage to a tube is too severe. at tube can be blocked or plugged as explained in “Tube Blocking.” No more than two tubes should ever be blocked on a core. Abo replace the core if more than three tabs are broken on one side, or if wo adjacent tabs are broken TANKS ‘The tanks ure attached to the core by the use of clinched tabs, The clinched tabs can be beat back if the tanks need to be removed from the core. Bend the tabs back only enough to remove the tanks. Overbending will weaken the tabs ‘A high temperature rubber gasket is used to seal the mating Surface between the core and the tank. The gasket must be replaced any time # tank is removed from the cove. TRANSMISSION OIL COOLER The transmisson cil evoler is located in one of the radiator side tanks, The vil cooler can be replaced by removing the tank from the core ALUMINUM RADIATOR SERVICE The aluminum-plastic radiator can be repaired at the dealership. The following components are asily replaced © Core + Tanks and gaskets. © Oil coolers and gaskets. The tanks cannot be repaired if broken or cracked. The radiator core can be replaced and the new core used with the original tanks and oil cooler. PRECAUTIONS ‘As with all cooling system service, sures fo prevent personal injury and damage to the system. tuke mea- CAUTION : To help avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, Scalding uid and steam can be blown out under pressare if the cap is taken off too soon, NOTICE: Do not use “boil out” tanks or vats Common service methods may actually destroy an ‘aluminum radiator, Caustic or lye cleaning solutions ust not be used for aluminum radiators + Do not open the hood if you can see, or heat, steam or coolant escaping from the engine compartment. © Do not remove the coolant recovery tank cap if the coolant in the recovery tank’ looks hike itis boili # Wear eye protection, @ Wear gloves to protect your hands ay: excessive heat, or the efforts of chemicals on your skin # Prevent dirt and water from entesin smisson oil cooler « Do not use boil-out tanks, or vats. or other tanks that have been sed for copper and briss radiators. The flux, acid, and caustic cleaners remaining in these tanks ‘will attack the alum inum and cause radiator failure. A separate test tank containing clean water is strongly recom- ended for servicing aluminum-plastic radiators, NOTICE: Never use shop atic that is not accurately regulated at 20 psi(I39\Pa to pressure test the radiator. Pressures over 20 psi(}38 kPa) will damage the radiator,A, cone 8. OULET TANK TRANSMISSION COOLER E, COOLER GASKET F. COOLER RETANNG NUT Figs DIAGNOSIS LEAK TESTING Some core leaks can be detected by merely adding water to the radiator. It is helpful to clan the core so that the damaged area can be more easily found. 1. Remove ditt and insets from the fins with a common water hose without a nozzle, Excessive water pressure could damage the fi 2. Scrub the core with & soft-bristle brush using clan, hot water, or hot water with a mild det gent solution. ON-VEHICLE PRESSURE TESTING You Gut pressure-iest the aluminum-plastic radiitor with ¢ common pump any With the system al a cool temperature, remove the recovers tink exp, connect the system) operating pressure, (138 KPa) Watch the gave needle for an indication of leak ond examine the radiator and other cooling system pats for § and apply normal Do not exeved 20 pst izns of escaping cookint Repair all hose and howe connections as. req Aluminum Radiator ENGINE COOLING 6¢- uited.Also check the reservoir tank cap to ensut that it will maintain the correct pressure. I the radiator is found to be leaking durin the pressure test, mark the leak area so that it easily found once the radiator has been remove from the vehicle OFF-VEHICLE LEAK TESTING NOTICE: Do not use boi-out tunks. or vats. ¢ other tanks that have been used for copper an brass radiators. The flux, acid, and caustic cleanes remaining in these tanks will attack the aluminur and cause radiator failure. A separate test tam containing clean water is strongly recommends for servicing aluminum-plastic J. Install test fittings or rubber test eps int the ink, and outlet necks and seal the oil cooker fitting with metal plugs to protect the cooler and kee the fluid from runsing out(Figure 6), 2 Attach a pressure tester and gradually apply a pressure until 20 psi(l38 kPa} ty atiained. Ds not exceed 20 psi(38 Kay. Check the pressur gaye to see if there is a pressure loss, To ensun hat there are no small leaks run water over th repair area and look for bubbles.(A mild dete Fgent is very helpful) 1f at large water tank: available, the empty radiator ean. be submerged and a check for air bubbles can be perlorm5C~8 ENGINE COOLING usser Test Cae Coote. Pues FE 6 Rumminam Radiator and 1 Cooler PUES REPAIRABLE LEAKS There are two types of leaks that can be rep~ aired on the aluminum-plstic radiator; core leaks ‘and gasket leaks. Leaks in the plastic tanks cannot be repaired ‘Core leaks can ovcur ia a tubs, oF in the joints between the tubes and headers, Gasket leaks ean occur in the joints between the plastic tanks and the headers, or in the joints between the oil cooler fittings and the tank. Some leaks can be repaired while the radiator is on the vehicle : howeverit is usually best to remove the radiator TANK GASKET LEAK REPAIR Tank gasket leaks can easily be mistak tank or header leaks. If a plastic tank leaks irom the header joint gasket. tighten the clinch tabs will locking-type plices(Figure 7). If this method doesn’t seal the Teak, remove the tank for further inspec tion, 1. Pry open the clinch tabs, except those under inlet, outlet. and filler necks, using j33419-1 or 3 serewdriver(Figure 8). Lift the tabs only enough to allow removal. NOTICE : Care should be taken not to over yend tabs, Overbending could result in beeak- tage, I there are more than 3 tabs broken on one side of the header, or more than 2 adjacent tabe together, the core must be replaced. 2 Lit the tank sand slide it out from under the remaining clinched tab. You may have to tap the tank with your hand to dislodge the gasket Lift the remaining tabis) with pliets. 3. Remove and discard the gasket. 4, Clean the header and gasket groove of all dirt and old rubber, 5. Ckan the sealing edge of the plastic tank ‘Su TOOL UNDER TH {AND PUSH BACK Fig 8 Opening Clinch Tabs 6. Examine th header gasket surface and tink flange for evidence of leakage, and clean or repair the surface to remove dirt, burrs, and bumps, 7. Remove the oil cooler. if equipped. and install iL in the new tank 8. Dip or coat the new tunk gasket in engine coolint and position it on the header surface The coolant helps hokd the gasket in place 9, Position the tank and gasket to. the header Clamp it in place and secure it by bending four Glinch tabs as shown(Figure 9) 10. Clamp the remaining clinch tabs around the header using the clinching tool or pliers. using sen(Figure 10), the sequence NOTICE cylinder heal bolts. startin working out to the ends Tighten the elinch tabs as you would at the center and IL. Replace the core if there are more than thretubs broken on one side or two adjacent tabs broken, 12. Install the drain cock, if removed. 13. Test the radiator for leaks BEN FOUR (CLINCH TABS “Fig. 10 Clinching Sequence OIL COOLER GASKET REPLACEMENT The outlet tink must be removed to replace the oil cooler, but the oil cooler gaskets can be replaced without removing the tank T Remove the radiator and kay ion a flat sur- hee Remove the bottom oil cooler aut and loosen the top nut 3. Press the oil cooler into the hole and remove the gusket using a small hook(Figure 11) 4. Blow-dry all surfaces on the tank and oil cooler 3. Install & new gasket without Lubrication. Be sure it is sealed properly inside the lip of the fitting Resch tnewabe indie or-oudleropaiingsndl pull: the cooler into position against the tank. 7. Asvemble the oil cooler nut loosely 8 Replace the other gasket by following the same ENGINE COOLING 6¢ procedure. 9. Install the oil cooler nuts and tighten to Nm. Do not overtighten, as damage to gasket could result 10, Leck-test the radiator ‘SMALL HOOK asker Fig. 11 Removing 01 Cooler Gasket OIL COOLER REPLACEMENT Remove the outlet tank as previously outline Remove nuts from the oil cooler fittings Remove oil cooler and gaskets from tank. Remove the old rubber gaskets, Throw t gaskets away and clean and dry the seal are: 5. Place rubber gaskets on a new oil cooler i place onto outlet tank fitting holes, being ¥ careful not to loosen or misalign gaskets. Gast must be installed dry and free of dirt and oil 6, Install and tighten riuts snugly onto fittings. 7. Tighten nuts to 20 N+ m Overtightening co cut the rubber guskets. . Replace tank as previously described. Test radiator, RECORE If the radiator core is damaged beyond rep and the other parts are serviceable. install original inlet and outlet tanks. cil cooler. and dr cock, onto a new core and install new gaskets, ON-VEHICLE SERVICE THERMOSTAT EF] Romove or Disconnect 1. Drain radiator throu; 2. Upper coolant hose. 3. Thermostat housing—three bolts 4. Thermostat.60-10 ENGINE COOUNG |. RADIATOR BRACKET 2 SHIM 3. SCREW 4, BUMPER 5, RADIATOR ASSEMBLY 6 BUMPER 7. BLOWER MOTOR 8 CLAMP 8, UPPER HOSE-RADIATOR 10. HOSE. 11 CLAMP 12, THERMOSTAT HOUSING Fig. 13. SEAL 4, BRACKET 15. CLAMP. 16. HOSE V7.LaMP 18, LAMP 19. HOsF 20, LAM? 21. SCREW 22, HOSE 23. HOSE 24. HOSE 12 Claoing System 2 26. Pa 28 3 32 33. 1 SCREW 35, 38, PIPE Lamp HOSE LOWER HOSE-RADIATOR SCREW SHRQUD-RADIATOR TANK RADIATOR RESERVOIR car HOSE CLAMP:60-10 ENGINE COOUNG |. RADIATOR BRACKET 2 SHIM 3. SCREW 4, BUMPER 5, RADIATOR ASSEMBLY 6 BUMPER 7. BLOWER MOTOR 8 CLAMP 8, UPPER HOSE-RADIATOR 10. HOSE. 11 CLAMP 12, THERMOSTAT HOUSING Fig. 13. SEAL 4, BRACKET 15. CLAMP. 16. HOSE V7.LaMP 18, LAMP 19. HOsF 20, LAM? 21. SCREW 22, HOSE 23. HOSE 24. HOSE 12 Claoing System 2 26. Pa 28 3 32 33. 1 SCREW 35, 38, PIPE Lamp HOSE LOWER HOSE-RADIATOR SCREW SHRQUD-RADIATOR TANK RADIATOR RESERVOIR car HOSE CLAMP:Clean « Sealing surfaces on head and thermostat housing, LMOTOR-ELEGIRG COOLING FAN IB SHROUD: RADIATOR 2,RADIATOR |8017-RADATOR SHAOUD Fig. 13. Fan and Shroud Assembly E tnstell or Connect 2. Thermostat housing sing new “O" ring seal Tighten + Housing bolts to 10. N =m 3. Coolant hoses. 4 Relill coolant, ELECTRIC COOLING FAN E] Remove or ‘onnect 1. Battery negative cable. 2 Harness from fan motor and fan shroud 3. Fan shroud to radiator support attaching bolts 4. Fan motor and shroud assembly CAUTION : Ifa fan blade is bent or dam any way, NO attempt should be made to repair and/or reuse the damaged pari. A bent or damaged fan assembly should always be replaced with a new fan assembly. It is essential that the fan assembly remain in proper balance, Balance cannot be ass tured once a fin assembly has been bent or dame: gcd. fan assembly that iy not in proper balance could fail and ly apart during subsequent use. adition ged in crowting an extremely dangerous © install or Connect 1, Fan motor and shroud assembly 2. Fan shroud to radiator support attaching bolts 3. Fan Fan harness to fan shroud 4. Battery negative cable. ENGINE COOLING 6C Fig, 14. Thermostat WATER PUMP ©) Remove or Disconnect Drain radiator (through lower hese), Front timing belt covers. Timing belt. Lower rear timing belt cover. Water pump. © Clean ‘Sealing surfaces on both pump and cylinder ca & Install or Connect |. Water pump. A.WATER PUMP BOLTS BLLOWER FEAR TIMING BELT COVER Fig. 15 Water Pump Bolts| Auncen ame Reuven FROM ENGINE 6C—12 ENGINE COOLING Important © Coat the sealing surfuce and new seal ring with grease Tighten ‘© Warter pump bolts to SN > ™ 2. Lower rear timing bell cover: 3. Timing belt 4. Front cover 5. Refill radiator with coolant. {8,SEALAWATER PUMP zi] LOCK SHOWING IMPELLER Fig 16 Water Pump Seal RADIATOR RESERVOIR TANK Remove or Disconnect 1. Howes from reservoir tank 2. Attaching serews and remove reservoir tank Fig. 17 Coolant Reservoir & clean @ Wash reservoir tank and cap with soap and) water. ©& install or Connect 1. Reservoir tank in vehicle and retain with appr priate Fasteners. 2, Coolant hoses to reservoir tank 3. Fill reservoir tank RADIATOR E]_ Remove or Disconnect 1 Battery negative cable 2 Drain cooling system (partially) through lower hose of radiator and remove 3, Hose from reservoir tank 4, Radiator upper hese 5. Connectors to, © Fan motor # Temperature sensor Bolts —radiator to radiator support Radiator Important © Radiator is still hull full of eookant 8. Fan shroud with fan motor 1 Install or Connect Fan motor with tan shroud ty radiator Radiator —athach to radiator support wit belts Connectors to # Fan moto: # Temperature sensor 4. Radiator lower hose 5. Hose to reservoir tank i) Refill radiator with eookint @ important # Bleed air through upper hose conection Hold hose in position until coolant rea cches upper hose position 7. Upper hove & Top aff reservoir tank coolant levelENGINE COOLING. Fig. 18 Radiator Hose Connection SPECIFICATIONS Oil Cooler Nuts openeseneetnae 20N + Therm it: Hsing: Boligssse-aeoisevessssecien sasevicxvcivideces daca issnaaemeegteceesteltbesistemeeeee TON Water Pump Bolt BN