Temperature Versus Resistance
| °C | °F | Sensor Resistance |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 100 | 212 | 155 |
| 90 | 194 | 208 |
| 80 | 176 | 283 |
| 70 | 158 | 392 |
| 60 | 140 | 552 |
| 50 | 122 | 793 |
| 45 | 113 | 958 |
| 40 | 104 | 1165 |
| 35 | 95 | 1425 |
| 30 | 86 | 1755 |
| 25 | 77 | 2176 |
| 20 | 68 | 2717 |
| 15 | 59 | 3428 |
| 10 | 50 | 4356 |
| 5 | 41 | 5578 |
| 0 | 32 | 7198 |
| 5 | 23 | 9362 |
| 10 | 14 | 12278 |
| 15 | 5 | 16229 |
| 20 | 4 | 21653 |
| 30 | 22 | 39631 |
| 40 | 40 | 75532 |
Temperature Versus Resistance
Reference Information
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS -- INDEX
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
- Ignition ON.
- Verify the scan tool Radiator Coolant Temperature Sensor parameter is between -39 to + 120°C (-38 to +248°F) and changes with engine run time. If not between -39 to + 120°C (-38 to +248°F) or does not change Refer to Circuit/System Testing below. If between -39 to + 120°C (-38 to +248°F) and changes
- Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
- Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
- «Engine Coolant Temperature Sensor Replacement (Radiator)»(ref-544476-S23999745222013042400000) , «Engine Coolant Temperature Sensor Replacement (Thermostat)»(ref-544476-S15306425632013042400000)
- «Engine Control Module Replacement»(ref-544476-S11678954272013042400000) engine control module replacement, programming, and setup
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS -- INDEX
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P0117, P0118, P0597, P0598, or P0599 should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-544470-S39215059612013042400000) for further diagnosis.
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) , and «Loss of Coolant»(ref-544478-S31842068892013042400000) .
- Engine idling for 15 minutes with the A/C OFF.
- Command the engine coolant thermostat heater to 100 percent with a scan tool. Increase the engine speed to 3, 000 RPM. Observe the scan tool radiator coolant temperature sensor and ECT sensor parameters. The radiator coolant temperature sensor and the ECT sensor parameters should be within 20°C (68°F).
- Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Engine Control Module Replacement»(ref-544476-S11678954272013042400000) for ECM replacement, setup, and programming
Schematic Reference
- «Engine Controls Schematics»(ref-544506-S10565999282013042400000)
- «Engine Heating/Cooling Schematics»(ref-544478-S16653041482013042400000)
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify that DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are not set. If DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are set Refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-544470-S39215059612013042400000) . If DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are not set
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. If the coolant in the radiator surge tank is not at the correct level or there are engine coolant leaks Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) , and «Loss of Coolant»(ref-544478-S31842068892013042400000) . If the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks
- Verify the engine cooling fan operates. If the engine cooling fan does not operate Refer to «Cooling Fan Inoperative (LL0)»(ref-544478-S35872772542013042400000) . If the engine cooling fan operates
- Engine idling for 15 min with the A/C OFF.
- Command the Engine Coolant Thermostat Heater to 100% with a scan tool. Increase the engine speed to 3 000 RPM. Observe the scan tool ECT sensor parameters. The temperature should decrease to less than 85°C (185°F). If the temperature does not decrease to less than 85°C (185°F) Refer to Circuit/System Testing below. If the temperature does decrease to less than 85°C (185°F)
- All OK.
Perform the Diagnostic Repair Verification after completing the repair.
Engine Coolant Thermostat Replacement
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS -- INDEX»(ref-545989)
- «Electrical Center Identification Views»(ref-544509-S01490001422013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify an audible click is heard or felt from each cooling fan relay when commanding the cooling fan ON and OFF with a scan tool. If a click is not heard or felt at each of the relays Refer to Circuit/System Testing below. If a click is heard or felt at each of the relays
- Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
- Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Perform the Diagnostic Repair Verification after completing the repair.
- «Relay Replacement (Within an Electrical Center)»(ref-544488-S02508123392013042400000) , «Relay Replacement (Attached to Wire Harness)»(ref-544488-S18974667042013042400000)
- «Control Module References»(ref-544475-S18239609172013042400000) for ECM replacement, programming, and setup
Schematic Reference
Connector End View Reference
COMPONENT CONNECTOR END VIEWS -- INDEX
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. «Loss of Coolant»(ref-544478-S31842068892013042400000) , and «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) If the coolant level is not correct Repair as necessary. If the coolant level is correct
- Ignition ON.
- Verify the parameters listed below do not display Malfunction when commanding the Engine Coolant Thermostat Heater ON and OFF with a scan tool. Engine Coolant Thermostat Heater Control Circuit Low Voltage Test Status Engine Coolant Thermostat Heater Control Circuit Open Test Status Engine Coolant Thermostat Heater Control Circuit High Voltage Test Status If Malfunction is displayed Refer to Circuit/System Testing below. If Malfunction is not displayed
- Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure records data.
- Verify the DTC does not set. If any DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Engine Coolant Thermostat Replacement»(ref-544478-S39979168742013042400000) for E41 Engine Coolant Thermostat Heater replacement.
- «Control Module References»(ref-544475-S18239609172013042400000) engine control module replacement, programming, and setup.
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS -- INDEX
Description and Operation
Cooling System Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117, or P0118 should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-544470-S39215059612013042400000) for further diagnosis.
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) , and «Loss of Coolant»(ref-544478-S31842068892013042400000) .
- Engine idling for 15 min with the A/C OFF. Verify the engine cooling fan is not ON at all times.
- Command the Engine Coolant Thermostat Heater to 0 % with a scan tool. Increase the engine speed to 3, 000 RPM. Observe the scan tool ECT sensor parameter. The temperature should increase to greater than 102°C (215°F). If less than the specified value, replace the E41 engine coolant thermostat heater.
- Operate the vehicle within the conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Engine Coolant Thermostat Replacement
Intermittent Conditions
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Symptoms - Engine Cooling .
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS -- INDEX»(ref-545989)
- «Electrical Center Identification Views»(ref-544509-S01490001422013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify that DTC P0480 or P0481 is not set. If any of the DTCs are set Refer to «DTC P0480 or P0481 (LL0)»(ref-544478-S05042452412013042400000) . If none of the DTCs are set
- Verify the scan tool parameters listed below display OFF: Cooling Fan Relay 1 Command Cooling Fan Relays 2 Command If a scan tool parameter displays ON Refer to Diagnostic Aids and «Symptoms - Engine Cooling»(ref-544478-S05294460432013042400000) for further diagnosis. If both scan tool parameters display OFF
- Verify that the fan is not activated. If a fan is operating Refer to Circuit/System Testing below. If the fan is OFF
- All OK.
Perform the Diagnostic Repair Verification after completing the repair.
Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS -- INDEX»(ref-545989)
- «Electrical Center Identification Views»(ref-544509-S01490001422013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-544474-S28522670622013042400000)
- «Connector Repairs»(ref-544474-S01694319662013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-544474-S10250380742013042400000)
- «Wiring Repairs»(ref-544474-S21510154002013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify that DTC P0480, P0481, P0691, P0692, P0693 or P0694 is not set. If a DTC is set Refer to . If no DTC is set
- Verify that the cooling fan operates at low and high speed, when commanding the appropriate cooling fan relays ON and OFF with a scan tool. If the cooling fan does not operate at all speeds Refer to Circuit/System Testing below. If the cooling fan operates at all speeds
- All OK.
Engine Overheating
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: Either of the following conditions indicate a probable engine overheat condition. The engine temperature gauge is in the red (overheat) zone and/or the engine temperature indicator is ON. Hot engine coolant overflows from the coolant recovery reservoir and/or coolant pressure cap onto the ground while the engine is running. | |||
| 1 | Inspect and fill the cooling system, as necessary. Inspect the cooling system for leaks, as necessary. Repair the cooling system leaks, as necessary. Has the inspection/repair been performed? | Go to Step 2 | |
| 2 | Start the engine and allow the engine to run at approximately 1 200 RPM. Use the Scan Tool in order to verify the overheat condition. Does the Scan Tool verify the engine overheat condition? | Go to Step 3 | Go to Engine Heating/Cooling Schematics |
| 3 | Verify that the cooling fans are operating correctly. Repair the cooling fan system, as necessary. Does the engine still overheat? | Go to Step 4 | System OK |
| 4 | Perform the following inspections: Inspect the radiator and the A/C condenser cooling fans for debris or any other obstruction Inspect the drive belt system and the drive belt tensioner for correct operation in order to ensure that the water pump is rotating correctly. Inspect for loose, damaged and/or missing air deflector(s). Check for a pinched or kinked cooling system hose. Repair the system if necessary. Does the engine still overheat? | Go to Step 5 | System OK |
| 5 | Inspect the thermostat for correct operation. Does the thermostat operating correctly? | Go to Step 7 | Go to Step 6 |
| 6 | Replace the thermostat. Does the engine still overheat? | Go to Step 7 | System OK |
| 7 | NOTE: Excessive coolant freeze point protection MAY cause the coolant to boil at low temperatures. Inspect for the correct coolant concentration (mixture). Correct the coolant concentration as necessary. Remove the coolant pressure cap. Start the engine and inspect for a constant flow of air bubbles in the engine coolant. Is there a constant flow of air bubbles in the engine coolant? | Go to Step 8 | Go to Step 9 |
| 8 | The probable cause of the engine overheat is combustion chamber gasses leaking into the cooling system. This condition is usually caused by the following: A worn or damaged cylinder head gasket. Worn or damaged cylinder head. A worn and/or damaged engine block. Verify this condition by inspecting the spark plug electrodes and porcelain surrounding the spark plug electrode for signs of coolant. Replace and/or repair the engine internal component(s), as necessary, in order to repair the engine internal coolant leak. Does the engine still overheat? | Go to Step 1 | System OK |
| 9 | The engine overheat may be caused by a cooling system blockage. Flush the cooling system. Does the engine still overheat? | Go to Step 10 | System OK |
| 10 | NOTE: It is unlikely that the water pump is the cause of the overheat condition. If NONE of the cooling system passages are restricted, replace the water pump.Does the engine still overheat? | Go to Step 1 | System OK |
| NOTE |
|---|
| Excessive coolant freeze point protection MAY cause the coolant to boil at low temperatures. |
| NOTE |
|---|
| It is unlikely that the water pump is the cause of the overheat condition. |
Engine Overheating
Loss of Coolant
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: Loss of coolant in the coolant system internally or externally. | |||
| 1 | Inspect the coolant level. Is the coolant at the correct level? | Go to Step 6 | Go to Step 4 |
| 2 | Fill the cooling system to the correct level. Is the action complete? | Go to Step 5 | |
| 3 | If the engine is suspected to have a coolant leak into a cylinder, the coolant can hydraulically lock the engine. Does the engine crankshaft rotate? | Go to Step 6 | Repair the condition in which the engine cannot be cranked. Go to Engine Will Not Crank - Crankshaft Will Not Rotate |
| 4 | Engine overheating can cause a loss of coolant. Is the engine overheating? | Go to Engine Overheating | Go to Step 7 |
| 5 | Extended operation with a low coolant level can cause engine internal component failure. Is the engine knocking? | Repair the engine knock. Refer to Lower Engine Noise, Regardless of Engine Speed | Go to Step 8 |
| 6 | Idle the engine at the normal operation temperature. Inspect for heavy white smoke coming out of the exhaust system. Is a heavy white smoke present from the exhaust pipe? | Go to Step 9 | Go to Step 10 |
| 7 | Coolant in the exhaust system creates a distinctive, burning coolant odor in the exhaust. Condensation in the exhaust system can cause an odorless white smoke during engine warm up. Does the white smoke have a burning coolant type odor? | Repair the engine internal coolant leak. Refer to Coolant in Engine Oil | Go to Step 10 |
| 8 | With the engine idling, inspect the coolant recovery reservoir. Does the coolant recovery system discharge coolant while the engine is idling? | Repair the engine internal coolant leak. Refer to Coolant in Engine Oil | Go to Step 11 |
| 9 | Visually inspect the hoses and hose retaining clamps at the following locations: Coolant bypass Coolant reservoir Heater core Coolant bypass valve Radiator Are any of the hoses leaking? | Repair or replace the leaking component. Refer to the appropriate repair. | Go to Step 12 |
| 10 | Visually inspect the following component: Coolant pressure cap Core plug Cylinder head gasket Engine block Intake manifold Radiator Thermostat housing Water pump Are any of the listed components leaking? | Repair or replace any leaky part. | Go to Step 13 |
| 11 | Pressure test the cooling system. With the cooling system pressurized, visually inspect the components listed in steps 11 and 12. Is there any leakage? | Repair or replace the leaking component. | Go to Step 14 |
| 12 | Pressure test the coolant pressure cap. Does the coolant pressure cap hold pressure? | Go to Step 13 | Replace the coolant pressure cap. |
| 13 | Inspect for the following conditions: A coolant smell inside of the vehicle. Coolant in the HVAC module drain tube. Coolant on the vehicle floor covering near the HVAC module. Is coolant present? | Replace the heater core. | Go to Step 15 |
| 14 | Inspect the underside of the engine oil filler cap for a gray/white milky substance. Is there a milky substance on under the oil fill cap? | Repair the engine internal coolant leak. Refer to Coolant in Engine Oil | Replace the coolant pressure cap. |
| 15 | Inspect the engine oil level indicator for a gray/white milky substance. Is there a milky substance on the engine oil level indicator? | Repair the engine internal coolant leak. Refer to Coolant in Engine Oil | Replace the coolant pressure cap. |
Loss of Coolant
Engine Fails To Reach Normal Operating Temperature
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Ensure that the cooling system is full. Allow the engine to cool. Start the engine. Turn the air conditioning system off. Inspect the engine cooling fan(s). Is the electric cooling fan on? | Go to Step 2 | Go to Step 3 |
| 2 | Diagnose and repair the cooling fan system. Verify the customer complaint. Does the engine still fail to reach normal operating temperature? | Go to Step 3 | System OK |
| 3 | Install the scan tool to the DLC. Compare the scan tool coolant temperature reading to the I/P cluster coolant temperature. Is the I/P cluster coolant temperature close to the reading on the scan tool? | Go to Step 5 | Go to Step 4 |
| 4 | Diagnose and repair the coolant temperature gauge system. Verify the customer complaint. Does the engine still fail to reach normal operating temperature? | Go to Step 5 | System OK |
| 5 | Inspect the thermostat for correct operation. Is the thermostat operating correctly? | System OK | Go to Step 6 |
| 6 | Replace the thermostat. Verify the customer complaint. Does the engine still fail to reach normal operating temperature? | Go to Step 1 | System OK |
Engine Fails To Reach Normal Operating Temperature
Filling Procedure
- Raise and support the vehicle.
- Tighten the radiator drain cock (1) to 2 (18 lb in).
- Lower the vehicle.
- Slowly fill the radiator with a 50/50 coolant mixture until the coolant level reaches the base of the radiator surge tank.
- Allow 30 seconds for the coolant level to stabilize and continue to fill the coolant filler neck until the level stabilizes for at least 2 minutes.
- Start the engine and allow the engine to idle in PARK or NEUTRAL with the parking brake engaged.
- Slowly fill the coolant mixture until the level stabilizes at the base of the radiator surge tank.
- Install the coolant pressure cap.
- Raise the engine RPM to 2500 RPM for 30-40 seconds.
- Shut the engine OFF.
- Allow the engine to cool, remove coolant fill cap and repeat steps 3-9 until the coolant level has completely stabilized within the radiator surge tank.
- Inspect and if necessary, fill the coolant reservoir bottle as necessary.
- Rinse away any excess coolant from the engine and the engine compartment.
- Inspect the cooling system for leaks.
- Top off the radiator surge tank if necessary.
Radiator Cleaning
| WARNING | NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. |
| CAUTION | The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. |
Note. Blow compressed air through the engine side of the radiator to remove any foreign material, such as insects, leaves, and dust.
- Warm water and mild soap may be needed in some conditions.
- Wash the A/C condenser fin.
- Wash the A/C condenser and radiator thoroughly.
- Wash the radiator cooling fin.
- Repair any damaged cooling fin.
Scheme 7
| Callout | Component Name |
|---|---|
| Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling . | |
| 1 | Block Heater Connecting Plug Holder Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 8 (71 lb in) |
| 2 | Radiator Surge Tank Mounting Bolt (Qty: 2) Tighten 8 (71 lb in) |
| 3 | Radiator Surge Tank Outlet Hose & Clamp |
| 4 | Radiator Surge Tank Inlet Hose & Clamp |
| 5 | Radiator Surge Tank |
| 6 | Block Heater Connecting Plug Holder |
| 7 | Coolant Hose & Clamp |
| CAUTION |
|---|
| Refer to Fastener Caution . |
Radiator Surge Tank Replacement
Radiator Mounting Stud Repair
Note. In this vehicle, mounting pin repair system is only applied to lower side of the radiator, not upper.
Note. If the radiator is leaky, replace it. Refer to Radiator Replacement .
- Pressure test the cooling system. Refer to «Cooling System Leak Testing»(ref-544478-S41672264102013042400000) .
- Grind the fracture surface (1) with a proper tool.
- Drill a persistent hole in center of the fracture surface, using a 6 mm (0.24 in) drill.
- Install the new radiator mounting pin (2). Install the nut (3).
Scheme 8
| Callout | Component Name |
|---|---|
| Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling . | |
| 1 | Radiator Overflow Hose Clamp (Qty: 2) |
| 2 | Radiator Overflow Hose Bracket Nut CAUTION: Refer to Fastener Caution . Procedure Remove the radiator overflow hose bracket nut. Tighten 9 (80 lb ft) |
| 3 | Radiator Overflow Hose |
| CAUTION |
|---|
| Refer to Fastener Caution . |
Radiator Overflow Hose Replacement
Scheme 9
| Callout | Component Name |
|---|---|
| Preliminary Procedures Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement . Disconnect the wiring harness plug of the engine cooling fan. | |
| 1 | Engine Coolant Fan Bolt (Qty: 3) Procedure Remove the engine coolant fan bolts. Tighten 3 (27 lb in) |
| 2 | Engine Coolant Fan Shroud |
| 3 | Engine Coolant Fan |
Engine Coolant Fan Replacement
Water Pump
The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The water pump is mounted on the front of the transverse-mounted engine and is driven by the accessory belt.
The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and cannot be disassembled.
Thermostat
A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The thermostat is mounted in the thermostat housing to the rear of the cylinder head. The thermostat stops the flow of the engine coolant from the engine to the radiator to provide faster warm-up, and to regulate the coolant temperature. The thermostat remains closed while the engine coolant is cold, preventing circulation of the engine coolant through the radiator.
As the engine warms, the thermostat opens. This allows the engine coolant to flow through the radiator where the heat is dissipated through the radiator. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine coolant temperature increases. When the engine coolant reaches a specified temperature, the wax pellet element in the thermostat expands and exerts pressure against the metal case, forcing the valve open. This allows the engine coolant to flow through the engine cooling system and cool the engine. As the wax pellet cools, the contraction allows a spring to close the valve. To provide fuel economy and low emission benefit during part load driving condition, the electric controlled thermostat enables changing the thermostat opening temperature. Basically, the thermostat begins to open at 105° C (221° F) and is fully open at 120° C (248° F) when the electric energy not assisted.
If a certain driving environment encountered that requiring better cooling performance, the ECM orders to put electric energy to the thermostat. The energized electric heater in the wax pellet gives thermal energy to the wax for assisting the wax expansion. Then the thermostat valve opens earlier than the specified coolant temperature. For this vehicle, the programmed temperature set value by the ECM is 105° C (221° F) for cold and part load driving mode and 90° C (194° F) for hot and full load driving mode.
Radiator
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin cross-flow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere.
The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.
The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
Surge Tank
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During vehicle use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant with bubbles.