Cooling System: Other Saab 9-5 II

Engine Coolant Indicators

1. The instrument panel cluster (IPC) shows the engine temperature on the temperature gauge. The value is sent on the data communication line from engine control module (ECM). When the coolant temperature is more than 128°C (262°F) IPC receives a discrete input from ECM requesting illumination.
2. The IPC performs the display test at the start of each ignition cycle. The IPC illuminates the TEMP indicator.

Coolant Level Control

The engine cooling system contains an engine coolant level switch to alert the driver in the event of a low coolant level. When the engine coolant level in the surge tank falls below a certain level, the coolant level switch opens. When the body control module (BCM) detects an open or a high voltage level on the coolant level indicator control circuit, for at least 10 seconds, it will send a GM LAN message to the driver information center (DIC) requesting display of the low coolant level message. There is approximately a 10-second delay before the BCM sends the GM LAN message to prevent the message from being displayed, due to coolant sloshing in the surge tank.

Coolant Heater

The optional engine coolant heater operates using AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather. The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use.

The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly.

Cooling Cycle

Coolant flows from the radiator outlet and into the water pump inlet. Some coolant flows from the water pump, to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost capability as the coolant warms up.

Coolant also flows from the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders where the coolant absorbs heat.

The coolant then flows through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat.

Coolant is also directed to the throttle body. There the coolant circulates through passages in the casting. During initial start up, the coolant assists in warming the throttle body.

From the cylinder heads, the coolant flows to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature, or the coolant will flow through the thermostat and into the radiator where the coolant is cooled. At this point, the coolant flow cycle is completed.

Efficient operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following components.

Coolant

Coolant is a solution that consist of half water and half antifreeze. The coolant leads off excess heat from the engine to the radiator where the heat is transferred to the atmosphere.

Radiator

The radiator is a heat exchanger consisting of a core and 2 tanks. The aluminum core is a tube and fin crossflow 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 also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes the drain cock and drain cock seal.

Heat is removed from the coolant as the coolant passes through the radiator. The fins on the core transfer heat from the coolant passing through the tubes. Air passing between the fins absorbs the heat and cools the coolant.

Pressure Cap

The pressure cap seals and pressurizes the cooling system. The cap contains a blow off, or pressure valve and a vacuum, or an atmospheric valve

1. The pressure valve is held against the seat by a spring that protects the radiator by relieving pressure that exceeds 15 psi.
2. The vacuum valve is held against the seat by a spring that permits opening of the valve to relieve vacuum created when the cooling system cools. The vacuum, if not relieved, might cause the radiator to collapse.

The pressure cap allows the cooling system pressure to build up when the temperature increases. As the pressure builds, the boiling point of the coolant increases. Therefore, the engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant becomes, the faster the heat transfers from the radiator into the cooler air.

The pressure in the cooling system can get too high. When the pressure exceeds the strength of the spring, the pressure valve rises, venting the excess pressure.

As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open. This equalizes the pressure in the cooling system with the atmospheric pressure, preventing the radiator from collapsing.

Coolant Recovery System

The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery reservoir is also called a recovery tank or expansion tank. This tank is partially filled with coolant and is connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator and the reservoir.

In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure within the cooling system gets too high, the pressure valve in the pressure cap will open. This allows the coolant, which has expanded due to heat, to flow through the overflow tube and into the recovery reservoir. As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions, no coolant is lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant recovery reservoir is the elimination of almost all air bubbles from the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.

Air Baffles and Seals

The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance.

Water Pump

The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is a flat plate mounted on the pump shaft with a series of flat or curved blades or vanes. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force. The impeller shaft is supported by one or more sealed bearings, which never need to be lubricated. With a sealed bearing, grease cannot leak out, and dirt and water cannot get in.

The water pump circulates coolant throughout the cooling system. The pump is driven by the crankshaft from the drive belt.

Thermostat

The thermostat is a coolant flow control component, whose purpose is to regulate the operating temperature of the engine. The thermostat utilizes a temperature sensitive wax-pellet element, which connects to a valve through a piston. Heating is causing the element to expand and exert pressure against a rubber diaphragm. This pressure forces the valve to open. Cooling causes the element to contract. This contraction allows a spring to push the valve closed.

When the coolant temperature is below 91°C (195°F), the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up quickly. After the coolant temperature reaches 91°C (195°F), the thermostat valve will open. The switch point will differ a little depending on engine. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, even after opening. This restriction creates a pressure difference which prevents cavitations at the water pump and forces coolant to circulate through the engine block.

For some engines a solenoid thermostat controlled by the ECM will open and close the circulation.

Transmission Oil Cooler

The transmission oil cooler is a heat exchanger and is located inside the right side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant that surrounds the oil cooler as the transmission fluid passes through the cooler.

The transmission oil pump circulates the fluid through the feed line to the oil cooler. The fluid then flows through the cooler while the engine coolant absorbs heat from the fluid. The fluid is then pumped through the return line to the transmission.

COOLING SYSTEM DTC INDEX

KR20C Cooling Fan Low Speed Relay

KR20D Cooling Fan High Speed Relay

KR20E Cooling Fan Speed Control Relay

KR20F Cooling Fan Relay

Electrical Information Reference

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Circuit/System Verification

1. With the engine running, check the DTC Info with a scan tool. DTC P0480 or P0481 are not set.
2. Command the cooling fans ON and OFF at low, medium, and high speed while observing the scan tool circuit test status parameters listed below: Cooling Fan Relay 1 Control Circuit Open, Low Voltage, and High Voltage Test Status Cooling Fan Relays 2 and 3 Control Circuit Open, Low Voltage, and High Voltage Test Status The parameters should display OK or Not Run in each of the commanded states.
3. 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.

Repair Instructions

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000) for ECM replacement, setup, and programming

Cooling Fan Medium Speed 1 Relay

Cooling Fan Medium Speed 2 Relay

Cooling Fan High Speed Relay

Cooling Fan Speed Control Relay

Cooling Fan Relay

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition ON, command the Cooling Fan Relay 1 ON and OFF with a scan tool. You should hear the KR20F Cooling Fan Relay, KR20E Cooling Fan Speed Control Relay, and KR20B Cooling Fan Medium Speed 2 Relay click when commanded ON and OFF.
2. Command the Cooling Fan Relay 2 ON and OFF with a scan tool. You should hear the KR20A Cooling Fan Medium Speed 1 Relay click when commanded ON and OFF.
3. Command the G10 Cooling Fan Motor operation through low, medium, and high speed operations with the scan tool Cooling Fan control. The G10 Cooling Fan Motor will increases from low speed, to medium speed, and high speed, and back down to OFF.
4. 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.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000) for Engine Control Module replacement, setup, and programming

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. With the engine running, read the DTC Info with a scan tool. DTC P0480, P0481, P0691, P0692, P0693 or P0694 are not set.
2. Command the cooling fans ON and OFF at high speed while observing the scan tool circuit test status parameters listed below: Cooling Fan Relay 1 Control Circuit Open, Low Voltage, and High Voltage Test Status Cooling Fan Relays 2 and 3 Control Circuit Open, Low Voltage, and High Voltage Test Status The parameters should display OK or Not Run in each of the commanded states.
3. 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.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000) for ECM replacement, setup, and programming

Cooling Fan Left High Speed Relay

Cooling Fan Left Low Speed Relay, Cooling Fan Speed Control Relay and Cooling Fan Right Low Speed Relay

Cooling Fan Medium Speed Relay

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Command the Cooling Fan Relay 1 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
2. If the relay does not operate correctly, refer to «P0480 00, P0691 00 and P0692 00»(ref-653648-S21726305112014090100000) .
3. Command the Cooling Fan Relay 2 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
4. If the relay does not operate correctly, refer to «P0481 00, P0693 00 and P0694 00»(ref-653648-S21726305112014090100000) .
5. Command the Cooling Fan Relay 3 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
6. If the relay does not operate correctly, refer to P0482, P0695 and P0696.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000) for ECM replacement, setup, and programming

Repair Verification

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.
3. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation. Ignition ON, observe that the fan is not activated.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Command the Cooling Fan Relay 1 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
2. If the relay does not operate correctly, refer to «COOLING FAN LEFT HIGH SPEED OUTPUT MALFUNCTION»(ref-653648-S30012127172014090100000) .
3. Command the Cooling Fan Relay 2 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
4. If the relay does not operate correctly, refer to «COOLING FAN LEFT LOW SPEED OUTPUT MALFUNCTION»(ref-653648-S34972499702014090100000) .
5. Command the Cooling Fan Relay 3 ON and OFF with a scan tool. The clicking sound of the relay should be heard when changing between the commanded states.
6. If the relay does not operate correctly, refer to «COOLING FAN MEDIUM SPEED OUTPUT MALFUNCTION»(ref-653648-S33831669772014090100000) .

Cooling Fan Left High Speed Output Malfunction

1. Ignition OFF, disconnect the KR20J Cooling Fan Left High Speed Relay.
2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit terminal and ground.
3. If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the K20 Engine Control Module.
4. Ignition OFF, disconnect the K20 Engine Control Module. Test for an infinite resistance between the relay coil control circuit terminal and ground.
5. If less than the specified value, test the relay coil control circuit for a short to ground.
6. Test for less than 5.0 ohms between relay coil control circuit terminal and K20 Engine Control Module terminal 94 X2.
7. If greater than the specified value, test the relay coil control circuit for an open/high resistance.
8. Test for 70-110 ohms between 85 and 86 of the KR20J Cooling Fan Left High Speed Relay.
9. If the resistance is not within the specified range, replace the KR20J Cooling Fan Left High Speed Relay.

Cooling Fan Left Low Speed Output Malfunction

1. Ignition OFF, disconnect the KR20G Cooling Fan Left Low Speed Relay.
2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit terminal and ground.
3. If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the K20 Engine Control Module.
4. Ignition OFF, disconnect the K20 Engine Control Module. Test for an infinite resistance between the relay coil control circuit terminal and ground.
5. If less than the specified value, test the relay coil control circuit for a short to ground.
6. Test for less than 5.0 ohms between relay coil control circuit terminal and K20 Engine Control Module terminal 94 X2.
7. If greater than the specified value, test the relay coil control circuit for an open/high resistance.
8. Test for 70-110 ohms between terminals 85 and 86 of the KR20G Cooling Fan Left Low Speed Relay.
9. If the resistance is not within the specified range, replace the KR20G Cooling Fan Left Low Speed Relay.

Cooling Fan Medium Speed Output Malfunction

1. Ignition OFF, disconnect the KR20A Cooling Fan Medium Speed 1 Relay.
2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit terminal and ground.
3. If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the K20 Engine Control Module.
4. Ignition OFF, disconnect the K20 Engine Control Module. Test for an infinite resistance between the relay coil control circuit terminal and ground.
5. If less than the specified value, test the relay coil control circuit for a short to ground.
6. Test for less than 5.0 ohms between relay coil control circuit terminal and K20 Engine Control Module terminal 94 X2.
7. If greater than the specified value, test the relay coil control circuit for an open/high resistance.
8. Test for 70-110 ohms between terminals 85 and 86 of the KR20A Cooling Fan Medium Speed 1 Relay.
9. If the resistance is not within the specified range, replace the KR20A Cooling Fan Medium Speed 1 Relay.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000)

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.

Identifying Intermittent Conditions

Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement, vibration or physical movement of a component. Refer to the following for a list to help determine an intermittent condition

1. Moisture and water intrusion in connectors, terminals, and components
2. Connector mating
3. Terminal contact
4. High resistance in circuits or components. High resistance can be a resistance, irrespective of size, that disrupts the function of components.
5. Harness that is located too tight, or chaffed circuits
6. High or low ambient temperature
7. High or low engine coolant temperatures
8. High underhood temperatures
9. Heat build up in component or circuit due to circuit resistance, poor terminal contact, or high electrical load
10. High or low system voltage
11. High vehicle load conditions
12. Rough road surface
13. Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
14. Incorrect installation of non-factory, aftermarket, and after factory add on accessories

If an intermittent is determined, refer to TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS for specific strategies in diagnosing intermittent conditions.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition OFF, verify the radiator surge tank is filled to the correct level, with engine coolant.
2. Ignition ON, command the instrument cluster indicators ON and OFF with a scan tool. The low coolant indicator lamp should turn ON and OFF as commanded.
3. Engine operating, The low coolant indicator should be OFF with the engine coolant at the correct level.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «ENGINE COOLANT LEVEL INDICATOR MODULE REPLACEMENT»(ref-653648-S27148930512014090100000)
2. «INSTRUMENT CLUSTER REPLACEMENT»(ref-653662-S13802595702014090100000)
3. «CONTROL MODULE REFERENCES»(ref-653639-S11210668452014090100000)

Low Speed

In low speed operation, the ECM applies ground to the coil side of the following relays with the cooling fan relay 1 control circuit

1. Cooling Fan Left Low Speed Relay
2. Cooling Fan Right Low Speed Relay
3. Cooling Fan Speed Control Relay

This energizes the relay coils. The low speed cooling fan relays supply power to the appropriate cooling fan motor through an internal fan resistor. The fan speed control relay contacts close and supply a direct ground path for the left cooling fan motor. The right cooling fan motor is connected to a dedicated ground. This results in both fans operating at low speed.

Medium Speed

In medium speed operation, the ECM commands the low speed fan relays, and the speed control relay off. The ECM simultaneously commands both of the cooling fan high speed relays on with the cooling fan relay 2 control circuit. The cooling fan motors are supplied power directly from the cooling fan high speed relays. The right cooling fan is connected to a dedicated ground, and operates at high speed. The left cooling fan is supplied a ground through the right cooling fan resistor and fan motor, which is connected to the de-energized cooling fan speed control relay. This results in the right cooling fan operating at a reduced speed.

High Speed

In high speed operation, the ECM applies a ground to the coil side of all five cooling fan relays. When energized, the high speed relays apply voltage directly to the cooling fans through the switch side of the relays. The energized cooling fan speed control relay provides a direct ground circuit for the left cooling fan. This arrangement allows each fan to receive full voltage and operate at high speed.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition OFF, disconnect the appropriate cooling fan relay.
2. If any of the above DTCs are set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000) .
3. Ignition ON, command the appropriate fan relay ON and OFF with a scan tool. Verify that the fans turn ON and OFF when changing between the commanded states.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «Engine Coolant Fan Motor Replacement (LAU/A28NER)»(ref-653648-S15118623292014090100000)

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs P0480, P0481, P0691, P0692, P0693 or P0694 are not set.
2. If any of the DTCs are set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000) .
3. Ignition ON, observe the scan tool Cooling Fan Relay 1 and Cooling Fan Relays 2 and 3 Command parameters. The parameters should display OFF.
4. Ignition ON, observe that the fans are not ON.

Both Fans ON

1. Ignition OFF, disconnect the KR20F cooling fan relay.
2. Ignition ON, verify that the cooling fans are not ON.
3. If the fans are OFF, test or replace KR20F relay.
4. Ignition OFF, disconnect the KR20C cooling fan low speed relay.
5. Ignition ON, verify that the cooling fans are not ON.
6. If the fans are OFF, test or replace KR20C relay.
7. Ignition OFF, disconnect the KR20M cooling fan left medium speed relay.
8. If the fans continue to operate, test the circuits listed below for: A short to ground in the KR20F relay switched control circuit for the X70 under hood relay block. A short to voltage in KR20C relay switched output circuit. A short to voltage in KR20M relay switched output circuit.
9. If all circuits test normal, test or replace the KR20M relay.

One Fan ON

1. Ignition OFF, disconnect the KR20D cooling fan high speed relay.
2. Ignition ON, verify that the cooling fan is not ON.
3. If the fan is OFF, test or replace KR20D relay.
4. Ignition OFF, disconnect the KR20N cooling fan right medium speed relay.
5. Ignition ON, verify that the cooling fan is not ON.
6. If the fan continues to operate, test the circuits listed below for: A short to voltage in KR20D relay switched output circuit. A short to voltage in KR20N relay switched output circuit.
7. If all circuits test normal, test or replace the KR20N relay.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Verify that DTCs P0480 00, or P0481 00 are not set.
2. If a DTC is set, refer to «DTC P0480, P0481, P0691, P0692, P0693, OR P0694 (LLU) DTC P0480, P0481, P0691, P0692, P0693, OR P0694 (LBW, LAU)»(ref-653648-S16616628872014090100000) for further diagnosis.
3. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.

In low speed operation, the ECM applies ground to the coil side of the following relays with the cooling fan relay 1 control circuit

1. Cooling Fan Left Low Speed Relay
2. Cooling Fan Right Low Speed Relay
3. Cooling Fan Speed Control Relay

This energizes the relay coils. The low speed cooling fan relays supply power to the appropriate cooling fan motor through an internal fan resistor. The fan speed control relay contacts close and supply a direct ground path for the left cooling fan motor. The right cooling fan motor is connected to a dedicated ground. This results in both fans operating at low speed.

In medium speed operation, the ECM commands the low speed fan relays, and the speed control relay off. The ECM simultaneously commands both of the cooling fan high speed relays on with the cooling fan relay 2 control circuit. The cooling fan motors are supplied power directly from the cooling fan high speed relays. The right cooling fan is connected to a dedicated ground, and operates at high speed. The left cooling fan is supplied a ground through the right cooling fan resistor and fan motor, which is connected to the de-energized cooling fan speed control relay. This results in the right cooling fan operating at a reduced speed.

In high speed operation, the ECM applies a ground to the coil side of all five cooling fan relays. When energized, the high speed relays apply voltage directly to the cooling fans through the switch side of the relays. The energized cooling fan speed control relay provides a direct ground circuit for the left cooling fan. This arrangement allows each fan to receive full voltage and operate at high speed.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition OFF, disconnect the appropriate cooling fan relay.
2. If any of the above DTCs are set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000) .
3. Ignition ON, command the appropriate fan relay ON and OFF with a scan tool. Verify that the fans turn ON and OFF when changing between the commanded states.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «ENGINE COOLANT FAN MOTOR REPLACEMENT (LAU/A28NER)»(ref-653648-S15118623292014090100000)

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition ON, read the DTC information with a scan tool. DTC P0480 or P0481, P0691, P0692, P0693 or P0694 are not set.
2. If a DTC is set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000) .
3. Command the cooling fans ON and OFF at low, medium, and high speed with a scan tool. Both cooling fans should turn ON and OFF in each of the commanded states. Refer to «DIAGNOSTIC AIDS»(ref-653648-S30772005402014090100000) .

KR20 Cooling Fan Relay

1. Ignition OFF, disconnect the cooling fan relay.
2. Test for 70-110 ohms between terminals 85 and 86.
3. If not within the specified range, replace the KR20 cooling fan relay.
4. Measure the resistance between the terminals listed below. The DMM should display OL. 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified range, replace the relay.
5. Install a 20 A fused jumper wire between relay terminal 86 and B+. Install a jumper wire between relay terminal 85 and ground. Test for less than 2 ohms between terminals 30 and 87.
6. If greater than the specified range, replace the relay.

G10 Engine Cooling Fan

1. Ignition OFF, disconnect the harness connector at the G10 engine cooling fan.
2. Connect a jumper wire between ground and the G10 ground circuit terminal 3.
3. Connect a 40 A fused jumper wire between B+ and the G10 fan B+ supply circuit terminal 1. The cooling fan should operate at a High speed.
4. If the cooling fan does not operate, replace the G10 engine cooling fan.
5. Connect a 40 A fused jumper wire between B+ and the G10 fan B+ supply circuit terminal 2. The cooling fan should operate at a reduced speed.
6. If the cooling fan does not operate, replace the G10 engine cooling fan.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «ENGINE COOLANT FAN MOTOR REPLACEMENT (LAU/A28NER)»(ref-653648-S15118623292014090100000)

In low speed operation, the ECM applies ground to the coil side of the following relays with the cooling fan relay 1 control circuit

1. Cooling Fan Left Low Speed Relay
2. Cooling Fan Right Low Speed Relay
3. Cooling Fan Speed Control Relay

This energizes the relay coils. The low speed cooling fan relays supply power to the appropriate cooling fan motor through an internal fan resistor. The fan speed control relay contacts close and supply a direct ground path for the left cooling fan motor. The right cooling fan motor is connected to a dedicated ground. This results in both fans operating at low speed.

In medium speed operation, the ECM commands the low speed fan relays, and the speed control relay off. The ECM simultaneously commands both of the cooling fan high speed relays on with the cooling fan relay 2 control circuit. The cooling fan motors are supplied power directly from the cooling fan high speed relays. The right cooling fan is connected to a dedicated ground, and operates at high speed. The left cooling fan is supplied a ground through the right cooling fan resistor and fan motor, which is connected to the de-energized cooling fan speed control relay. This results in the right cooling fan operating at a reduced speed.

In high speed operation, the ECM applies a ground to the coil side of all five cooling fan relays. When energized, the high speed relays apply voltage directly to the cooling fans through the switch side of the relays. The energized cooling fan speed control relay provides a direct ground circuit for the left cooling fan. This arrangement allows each fan to receive full voltage and operate at high speed.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs P0480, P0481, P0482, P0691, P0692, P0693, P0694, P0695 or P0696 are not set.
2. If any of the above DTCs are set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000) .
3. Ignition ON, command the appropriate fan relay ON and OFF with a scan tool. Verify that the fans turn ON and OFF when changing between the commanded states.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «ENGINE COOLANT FAN MOTOR REPLACEMENT (LAU/A28NER)»(ref-653648-S15118623292014090100000)

In low speed operation, the ECM applies ground to the coil side of the following relays with the cooling fan relay 1 control circuit

1. Cooling Fan Left Low Speed Relay
2. Cooling Fan Right Low Speed Relay
3. Cooling Fan Speed Control Relay

This energizes the relay coils. The low speed cooling fan relays supply power to the appropriate cooling fan motor through an internal fan resistor. The fan speed control relay contacts close and supply a direct ground path for the left cooling fan motor. The right cooling fan motor is connected to a dedicated ground. This results in both fans operating at low speed.

In medium speed operation, the ECM commands the low speed fan relays, and the speed control relay off. The ECM simultaneously commands both of the cooling fan high speed relays on with the cooling fan relay 2 control circuit. The cooling fan motors are supplied power directly from the cooling fan high speed relays. The right cooling fan is connected to a dedicated ground, and operates at high speed. The left cooling fan is supplied a ground through the right cooling fan resistor and fan motor, which is connected to the de-energized cooling fan speed control relay. This results in the right cooling fan operating at a reduced speed.

In high speed operation, the ECM applies a ground to the coil side of all five cooling fan relays. When energized, the high speed relays apply voltage directly to the cooling fans through the switch side of the relays. The energized cooling fan speed control relay provides a direct ground circuit for the left cooling fan. This arrangement allows each fan to receive full voltage and operate at high speed.

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs P0480, P0481, P0482, P0691, P0692, P0693, P0694, P0695 or P0696 are not set.
2. If any of the above DTCs are set, refer to «Cooling System DTC Index»(ref-653648-S15574419622014111100000)
3. Ignition ON, command the appropriate fan relay ON and OFF with a scan tool. Verify that the fans turn ON and OFF when changing between the commanded states.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «ENGINE COOLANT FAN MOTOR REPLACEMENT (LAU/A28NER)»(ref-653648-S15118623292014090100000)

1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

1. Verify that DTCs P0480 00, or P0481 00 are not set.
2. If a DTC is set, refer to «DTC P0480, P0481, P0691, P0692, P0693, OR P0694 (LLU) DTC P0480, P0481, P0691, P0692, P0693, OR P0694 (LBW, LAU)»(ref-653648-S16616628872014090100000) for further diagnosis.
3. Command the Fan Relay 1 ON and OFF with a scan tool. The fan should turn ON at low speed and OFF with each command.
4. If the fan does not operate correctly, go to low speed operation malfunction.
5. Command the Fan Relay 2 and 3 ON and OFF with a scan tool. The fan should turn ON at medium speed and OFF with each command.
6. If the fan does not operate correctly, go to medium speed operation malfunction.
7. Command the Fan Relay 1, 2, and 3 ON and OFF with a scan tool. The fan should turn ON at high speed and OFF with each command.
8. If the fan does not operate correctly, go to high speed operation malfunction.

Low Speed Malfunction

1. Ignition OFF, disconnect the relays listed below: KR20B Cooling Fan Medium Speed 2 Relay KR20E Cooling Fan Speed Control Relay KR20F Cooling Fan Relay
2. Test for less than 1 ohms between the relay controlled output circuit terminal of the KR20F Cooling Fan Relay and ground.
3. If greater than the specified range, test the output circuit for an open/high resistance.
4. Verify that a test lamp illuminates between the relay coil ignition circuit terminal of the KR20B Cooling Fan Medium Speed 2 Relay connector and ground.
5. If the test lamp does not illuminate, test the relay coil ignition circuit for an open/high resistance.
6. Verify that a test lamp illuminates between the relay switch B+ circuit terminal of the KR20B Cooling Fan Medium Speed 2 Relay connector and ground.
7. If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the relay controlled output circuit terminals of the relay connectors listed below for a short to ground KR20A Cooling Fan Medium Speed 1 Relay KR20B Cooling Fan Medium Speed 2 Relay
8. Install a 10 A fused jumper wire between the relay coil ignition circuit terminal and the relay coil control circuit terminal of the KR20B Cooling Fan Medium Speed 2 Relay connector.
9. Verify that a test lamp illuminates between the relay switch ignition circuit terminal and the relay controlled output circuit terminal at the KR20E Cooling Fan Speed Control Relay connector.
10. If the test lamp does not illuminate, test the relay switch ignition circuit terminal at the KR20F Cooling Fan Relay connector for a short to ground or an open/high resistance.
11. Disconnect the harness connector at the G10 Cooling Fan Motor.
12. Test for less than 1.0 ohms between the G10 Cooling Fan Motor ground circuit terminal 1 and ground.
13. If greater than the specified range, test the ground circuit for an open/high resistance.
14. Connect the harness connector at the G10 Cooling Fan Motor.
15. Connect a 60 A fused jumper wire between the relay switch B+ circuit terminal and the relay controlled output circuit terminal of the KR20B Cooling Fan Medium Speed 2 Relay connector. Verify the cooling fan is activated at low speed.
16. If the cooling fan does not activate at low speed, test the output circuit for an open/high resistance. If the circuit tests normal, test or replace the cooling fan.
17. If all circuits test normal, test the relays listed below for correct operation and replace the faulty relay: KR20F Cooling Fan Relay KR20B Cooling Fan Medium Speed 2 Relay

Medium Speed Malfunction

1. Ignition OFF, disconnect the KR20A Cooling Fan Medium Speed 1 Relay.
2. Verify that a test lamp illuminates between the relay coil ignition circuit terminal and ground.
3. If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance.
4. Verify that a test lamp illuminates between the relay switch B+ circuit terminal and ground.
5. If the test lamp does not illuminate, test the B+ circuit for an open/high resistance.
6. Connect a 60 A fused jumper wire between the relay switch B+ circuit terminal and the relay controlled output circuit terminal. Verify the cooling fan is activated at medium speed.
7. If the cooling fan does not activate at low speed, test the output circuit for an open/high resistance. If the circuit tests normal, test or replace the G10 Cooling Fan Motor.
8. Test for less than 1 V between the relay coil control circuit terminal and ground.
9. If greater than the specified range, test the control circuit for a short to voltage. If the circuit tests normal, test the KR20E Cooling Fan Speed Control Relay for correct operation. If the relay tests normal, replace the K20 Engine Control Module.
10. If all circuits test normal, test or replace the KR20A Cooling Fan Medium Speed 1 Relay.
11. If greater than the specified range, test the ground circuit for an open/high resistance.

High Speed Malfunction

1. Ignition OFF, disconnect the relays listed below: KR20D Cooling Fan High Speed Relay KR20E Cooling Fan Speed Control Relay
2. Verify that a test lamp illuminates between the relay coil ignition circuit terminal of the KR20E Cooling Fan Speed Control Relay connector and ground.
3. If the test lamp does not illuminate, test the ignition circuit for an open/high resistance.
4. Verify that a test lamp illuminates between the relay switch ignition circuit terminal of the KR20E Cooling Fan Speed Control Relay connector and ground.
5. If the test lamp does not illuminate, test the ignition circuit for an open/high resistance.
6. Install a 10 A fused jumper wire between the relay switch ignition circuit terminal and the relay controlled output circuit terminal of the KR20E Cooling Fan Speed Control Relay connector.
7. Verify that a test lamp illuminates between the relay coil ignition circuit terminal of the KR20D Cooling Fan High Speed Relay connector and ground.
8. If the test lamp does not illuminate, test the ignition circuit terminal for an open/high resistance.
9. Verify that a test lamp illuminates between the relay switch B+ circuit terminal of the KR20D Cooling Fan High Speed Relay connector and ground.
10. If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the relay controlled output circuit for a short to ground. If the circuit tests normal, test or replace the G10 Cooling Fan Motor.
11. Connect a 60 A fused jumper wire between the relay switch B+ circuit terminal and the relay controlled output circuit terminal to the KR20D Cooling Fan High Speed Relay connector. Verify the cooling fan is activated at high speed.
12. If the cooling fan does not activate at low speed, test the output circuit for an open/high resistance. If the circuit tests normal, test or replace the G10 Cooling Fan Motor.
13. If all circuits test normal, test the relays listed below for correct operation and replace the faulty relay: KR20E Cooling Fan Speed Control Relay KR20D Cooling Fan High Speed Relay

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

1. «RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)»(ref-653659-S31726074922014090100000)
2. «ENGINE COOLANT FAN MOTOR REPLACEMENT (LAU/A28NER)»(ref-653648-S15118623292014090100000)

Engine Overheating

Loss of Coolant

Engine Fails To Reach Normal Operating Temperature

Correction

1. 01 - Replacement
2. 02 - Removal - Refit
3. 03 - Renovate
4. 04 - Paint
5. 05 - Adjust
6. 06 - Change comp. unit
7. 07 - Lubricate - Clean - Polish
8. 08 - Check/Fault search
9. 09 - Expose
10. 10 - Install new
11. 11 - Transfer

Procedure

Note. Use only a GM released anti-freeze mixture and ensure a concentration of 50% water to 50% antifreeze. Antifreeze does not just prevent the cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added, even in tropical countries.

In addition to the anti-freeze mixture, water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of regenerated sea water is not suitable.

Damage may also be caused to the engine if unauthorized anti-freeze agent is used.

If radiator, cylinder head or cylinder head seal have been replaced the old coolant must not be re-used.

1. Open cooling system. Unscrew coolant surge tank cap.
2. For draining the cooling system, open the drain screw (1) on the radiator.

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

1. Vehicles with air condition: switch air conditioning off.
2. After draining the system, close the drain screw on the radiator.
3. Open the vent screw (1) on the radiator.
4. Disconnect the quick connector (1) of the heater core inlet hose.
5. NOTE: Connect the quick connector of the heater core inlet hose and close the vent screw when coolant flows out. At first top up coolant until cold level of the coolant expansion tank. When the coolant has stopped dropping top up the coolant until the bottom line of the down pipe hole (black arrow).
6. Cap the cooling system screw in coolant surge tank cap.
7. NOTE: After removing the heater core (located in passenger room) the following additional work has to be done: Immediately after the engine starts kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM. Start and warm up the engine. Warm up engine at idle speed up to 2500 RPM until first radiator fan setting switches on.
8. NOTE: Remove the heater core (in the cabin) and run the engine for 2 minutes at 2 000 to 2 500 RPM. This guarantees that the whole cooling system is bled. Vent cooling system. Kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM.
9. Switch the engine off and let the engine cool down.
10. NOTE: After a test drive let the engine cool down and check the coolant level. Check coolant level and correct if necessary. The correct cold mark (fill-level) of the degassed system is the existing internal cold mark (1) plus 11 mm (0.43 in), which is an additional amount of 200 ml (6.76 oz).
11. Check the fill-level again. The distance among the fill stud and the fill-level must be 58 mm (2.2 in).
12. Close cooling system. Screw coolant surge tank cap.

Note. Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added, even in tropical countries.

In addition to the anti-freeze mixture, water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of regenerated sea water is not suitable.

Damage may also be caused to the engine if unauthorized anti-freeze agent is used.

If radiator, cylinder head or cylinder head seal have been replaced the old coolant must not be re-used.

Scheme 88

1. Open cooling system. Unscrew coolant surge tank cap.
2. For draining the cooling system, open the drain screw (1) on the radiator.

Scheme 89

Scheme 90

Scheme 91

Scheme 92

1. Vehicles with air condition: switch air conditioning off.
2. After draining the system, close the drain screw on the radiator.
3. Open the vent screw (1) on the radiator.
4. Open vent screw (1) on thermostat housing.
5. NOTE: Close vent screw of radiator and thermostat-housing when coolant flows out on that loosen vent screw. Top up coolant up to the bottom line of the bleed nozzle on the surge tank. When the coolant has stopped dropping top up the coolant until the bottom line of the down pipe hole (black arrow).
6. Cap the cooling system screw in coolant surge tank cap.
7. NOTE: After removing the heater core (located in passenger room) the following additional work has to be done: Immediately after the engine starts kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM. Start and warm up the engine. Warm up engine at idle speed up to 2500 RPM until first radiator fan setting switches on.
8. NOTE: Remove the heater core (in the cabin) and run the engine for 2 minutes at 2 000-2 500 RPM. This ensures that the whole cooling system is bled. Vent cooling system Kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM.
9. Switch the engine off and let the engine cool down.
10. NOTE: After a test drive let the engine cool down and check the coolant level. Adjust the coolant level to "Cold" mark if necessary. Check coolant level and correct the coolant to "COLD" mark if necessary.

Note. Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added, even in tropical countries.

In addition to the anti-freeze mixture, water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of regenerated sea water is not suitable.

Damage may also be caused to the engine if unauthorized anti-freeze agent is used.

If radiator, cylinder head or cylinder head seal have been replaced the old coolant must not be re-used.

Scheme 93

1. Open cooling system. Unscrew coolant surge tank cap.
2. For draining the cooling system, open the drain screw (1) on the radiator.

Scheme 94

Scheme 95

Scheme 96

Scheme 97

1. Vehicles with air condition: switch air conditioning off.
2. After draining the system, close the drain screw on the radiator.
3. Open cooling system. Unscrew coolant surge tank cap.
4. Disconnect the quick fitting (1) on the T-connector of the engine feeding hose.
5. Insert a hose with a funnel (1) in the opening of the T-connector (2) and top up with coolant.
6. Connect the quick fitting bleeding hose to the T-connector of the engine feeding hose.
7. Top up coolant up to the "COLD" mark of the coolant surge tank. When the coolant has stopped dropping top up the coolant until the "COLD" mark (black arrows).
8. Cap the cooling system. Screw coolant surge tank cap.
9. NOTE: After removing the heater core (located in passenger room) the following additional work has to be done: Immediately after the engine starts kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM. Start and warm up the engine. Warm up engine at idle speed up to 2500 RPM until first radiator fan setting switches on.
10. Vent cooling system Kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2500 RPM.
11. Switch the engine off and let the engine cool down.
12. Check coolant level and correct the coolant to "COLD" mark if necessary (black arrows).

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Master Electrical Component List

Link to end views of connectors: COMPONENT CONNECTOR END VIEWS .

List of components

Scheme 102

Scheme 103

Scheme 104