14-1

GROUP 14

ENGINE COOLING
CONTENTS

GENERAL INFORMATION . . . . . . . . 14-2 ENGINE COOLANT CHANGE . . . . . . . . . . 14-17

WATER PUMP COOLANT LEAK CHECK . 14-18
SERVICE SPECIFICATIONS. . . . . . . 14-2 ENGINE COOLANT CONCENTRATION
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
COOLANT . . . . . . . . . . . . . . . . . . . . . 14-3 COOLING FAN RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-3 COOLING FAN MOTOR CHECK . . . . . . . . 14-21

ENGINE COOLING DIAGNOSIS . . . . 14-3 THERMOSTAT . . . . . . . . . . . . . . . . . . 14-22

REMOVAL AND INSTALLATION . . . . . . . . 14-22
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-24
TROUBLESHOOTING STRATEGY . . . . . . 14-3
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3
WATER PUMP . . . . . . . . . . . . . . . . . . 14-25
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-4
REMOVAL AND INSTALLATION . . . . . . . . 14-25
SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-14
WATER HOSE AND WATER PIPE . . 14-26
ON-VEHICLE SERVICE. . . . . . . . . . . 14-16 REMOVAL AND INSTALLATION . . . . . . . . 14-26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-30
ENGINE COOLANT LEAK CHECK . . . . . . 14-16
RADIATOR CAP OPENING PRESSURE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-31
REMOVAL AND INSTALLATION . . . . . . . . 14-31
14-2 ENGINE COOLING
GENERAL INFORMATION

GENERAL INFORMATION
M1141000101255
The cooling system is designed to keep every part of ature, the thermostat opens to circulate the coolant
the engine at appropriate temperature in whatever through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced circu- The water pump is of the centrifugal impeller type
lation type in which the water pump pressurizes cool- and is driven by the drive belt from the crankshaft.
ant and circulates it throughout the engine. If the The radiator is the corrugated fin, cross flow type.
coolant temperature exceeds the prescribed temper-

CONSTRUCTION DIAGRAM
Radiator condenser
tank assembly

Radiator upper hose

assembly
Radiator assembly
Radiator fan motor

One-touch joint

One-touch
joint
Condenser fan motor

Cooling fan shroud

Radiator
lower Radiator lower hose
hose
Radiator lower pipe
AC705530 AC

SERVICE SPECIFICATIONS
M1141000301204

Item Standard value Limit

Valve opening pressure of radiator cap kPa (psi) 93 −123 (14 −18) Minimum 83 (12)
Thermostat Valve opening temperature of thermostat ° C (° F) 76.5 ± 1.5 (170 ± 3) −
Full-opening temperature of thermostat ° C (° F) 90 (194) −
Valve lift mm (in) 8.5 (0.33) or more −

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 ENGINE COOLING
COOLANT
14-3
COOLANT
M1141000401115

Item Quantity dm3 (qt)

Long life antifreeze coolant or an equivalent 7.5 (7.9)

SEALANT
M1141000501112

Item Specified sealant

Engine coolant temperature sensor Three bond 1324N, LOCTITE 262 or equivalent

ENGINE COOLING DIAGNOSIS

INTRODUCTION
M1141005300422
The system cools the engine so that it does not over-
heat and maintains the engine at an optimum tem-
perature. The system components are the radiator,
water pump, thermostat, radiator fan and condenser
fan assembly. Possible faults include low coolant,
contamination, belt loosening and component dam-
age.
TROUBLESHOOTING STRATEGY
M1141005200414
Use these steps to plan your diagnostic strategy. 2. Verify that the condition described by the
If you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find an 3. Find the malfunction by following the Symptom
engine cooling faults. Chart.
1. Gather information from the customer. 4. Verify that the malfunction is eliminated.
SYMPTOM CHART
M1141005600650

Symptom Inspection procedure Reference page

Coolant leak 1 P.14-4
Engine overheating 2 P.14-5
Radiator fan and condenser fan do not operate 3 P.14-6

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14-4 ENGINE COOLING
ENGINE COOLING DIAGNOSIS

SYMPTOM PROCEDURES

Inspection Procedure 1: Coolant Leak

DIAGNOSIS

STEP 1. Check for coolant leaks.

WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
CAUTION
• Be sure to completely clean away any moisture from
the places checked.
• When the tester is removed, be careful not to spill any
coolant.
• When installing and removing the tester and when test-
ing, be careful not to deform the filler neck of the radia-
tor.
Check that the coolant level is up to the filler neck. Install a radi-
ator tester and apply 160 kPa (23 psi) pressure, and then check
Cap adapter
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or
Adapter connections?
YES : Repair or replace the appropriate part, then go to
Step 2.
NO : There is no action to be taken.

ACX01844 AE

STEP 2. Retest the system.

Q: It there still coolant leakage?
YES : Return to Step 1.
NO : The procedure is complete.

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 ENGINE COOLING
ENGINE COOLING DIAGNOSIS
14-5

Inspection Procedure 2: Engine Overheating

DIAGNOSIS

STEP 1. Remove the radiator cap and check for coolant

contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace the coolant (Refer to P.14-17). Then go to
Step 5.
NO : There is no action to be taken. Go to Step 2.

STEP 2. Check the radiator cap valve opening pressure.

NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops
moving.
Cap adapter
Minimum limit: 83 kPa (12 psi)
Standard value: 93 −123 kPa (14 −18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
ACX01845AE

STEP 3. Check thermostat operation.

Refer to P.14-24.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat (Refer to P.14-22). Then go to
Step 5.

STEP 4. Check the drive belt for slippage or damage.

Refer to GROUP 00, Maintenance Service −Drive Belts (Check
Condition) P.00-66.
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt. Then go to Step 5.
NO : There is no action to be taken.

STEP 5. Retest the system.

Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
YES : Return to Step 2.
NO : The procedure is complete.

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14-6 ENGINE COOLING
ENGINE COOLING DIAGNOSIS

Inspection Procedure 3: Radiator Fan and Condenser Fan do not Operate

Radiator Fan and Condenser Fan Drive Circuit <M/T>

FUSIBLE FUSIBLE
LINK 28 LINK 29 INPUT SIGNAL INPUT SIGNAL
ENGINE ·FRONT WHEEL
COOLANT SPEED SENSOR
TEMPERATURE ·REAR WHEEL
SENSOR SPEED SENSOR

RADIATOR
FAN RELAY ENGINE ASC-ECU
CONTROL
MODULE

RADIATOR
FAN
MOTOR

JOINT
CONNECTOR
(CAN3)

INPUT SIGNAL
A/C SWITCH

CONDENSER FAN A/C-ECU

FAN RELAY CONTROL
RELAY

CONDENSER
FAN MOTOR

JOINT JOINT
CONNECTOR CONNECTOR
(CAN1) (CAN2)

ETACS-ECU
INTERFACE INTERFACE
CIRCUIT CIRCUIT

CAN DRIVE CAN DRIVE

CIRCUIT CIRCUIT

AC708832 AB

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 ENGINE COOLING
ENGINE COOLING DIAGNOSIS
14-7

Radiator Fan and Condenser Fan Drive Circuit <TC-SST>

FUSIBLE FUSIBLE INPUT SIGNAL INPUT SIGNAL

LINK 28 LINK 29
ENGINE ·FRONT WHEEL
COOLANT SPEED SENSOR
TEMPERATURE ·REAR WHEEL
SENSOR SPEED SENSOR

RADIATOR ENGINE ASC-ECU

FAN RELAY CONTROL
MODULE

RADIATOR
FAN
MOTOR
JOINT
CONNECTOR
(CAN2)

JOINT
CONNECTOR
(CAN3)

INPUT SIGNAL
CONDENSER FAN A/C SWITCH
FAN RELAY CONTROL
RELAY
A/C-ECU

CONDENSER
FAN MOTOR

JOINT JOINT
CONNECTOR CONNECTOR
(CAN1) (CAN2)

ETACS-ECU
INTERFACE INTERFACE
CIRCUIT CIRCUIT

CAN DRIVE CAN DRIVE

CIRCUIT CIRCUIT

AC708952 AB

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14-8 ENGINE COOLING
ENGINE COOLING DIAGNOSIS

Connectors: A-35X, A-36X, A-37X Connectors: A-45, A-47

Air cleaner Radiator
assembly

A-36X

A-47 (B) A-45 (B)

Engine
compartment
relay box
A-35X A-37X AC708833AB AC708834AB

Connector: C-312
ETACS-ECU

AC708835AB

• The radiator fan and condenser fan do not oper-

.

CIRCUIT OPERATION ate also when the CAN bus line, MFI system, or
• The ECM transmits the rotation signals of radiator ETACS system have a failure.
fan and condenser fan, based on the engine cool-
ant temperature signal from the engine coolant .

temperature sensor, the vehicle speed signal TROUBLESHOOTING HINTS

from the wheel speed sensor via the ASC-ECU, • Malfunction of CAN bus line
and the A/C switch signal from the A/C-ECU • Malfunction of MFI system
using the CAN bus line. • Malfunction of ETACS system
• The rotation signals of radiator fan and con- • Damaged wiring harness or connector
denser fan, using the CAN bus line from ECM, • Malfunction of fusible link number 28
turn ON/OFF of the radiator fan relay, condenser • Malfunction of fusible link number 29
fan relay, and fan control relay via ETACS-ECU, • Malfunction of radiator fan relay
to control the radiator fan and condenser fan rota- • Malfunction of condenser fan relay
tion. • Malfunction of fan control relay
• Malfunction of radiator fan motor
• Malfunction of condenser fan motor
.

TECHNICAL DESCRIPTION • Malfunction of ECM

• When the radiator fan and condenser fan do not • Malfunction of ETACS-ECU
operate, the wiring harness/connector, fan motor,
relay, and ETACS-ECU may have a failure.

DIAGNOSTIC PROCEDURE
Required Special Tools:
• MB991958: Scan Tool (M.U.T.-III Sub Assembly)
• MB991824: V.C.I.
• MB991827: M.U.T.-III USB Cable
• MB991910: M.U.T.-III Main Harness A
• MB991223: Harness Set
• MB992006: Extra Fine Probe

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 ENGINE COOLING
ENGINE COOLING DIAGNOSIS
14-9
CAUTION
If there is any problem in the CAN bus lines, an incorrect
diagnostic trouble code may be set. Prior to this diagno-
sis, diagnose the CAN bus lines (Refer to GROUP 54C,
Trouble code diagnosis P.54C-9).

STEP 1. Using scan tool MB991958, check the CAN bus

line diagnostics.
Use scan tool to diagnose the CAN bus line (Refer to GROUP
54C, Explanation About The Scan Tool Can Bus Diagnostics
P.54C-9).
Q: Is the diagnostic trouble code set?
YES : Go to Step 2.
NO : Repair the CAN bus line (Refer to GROUP 54C,
Diagnosis −Can Bus Diagnostic Table P.54C-14).
Then go to Step 22.

STEP 2. Using scan tool MB991958, check the MFI system

actuator test.
Using scan tool to check the MFI system actuator test (Refer to
GROUP 13A, MFI Diagnosis −Diagnostic Function P.13A-9).
• Item 14: Cooling fan
(Refer to GROUP 13A, MFI Diagnosis −Actuator Test Refer-
ence Table P.13A-871)
Q: Is the check result normal?
YES : Go to Step 21.
NO : Go to Step 3.

STEP 3. Using scan tool MB991958, read the MFI system

diagnostic trouble code (DTC).
Using scan tool to read the MFI system DTC (Refer to GROUP
13A, MFI Diagnosis −Diagnostic Function P.13A-9).
Q: Is any DTC set?
YES : Repair the MFI system (Refer to GROUP 13A, MFI
Diagnosis −Diagnostic Trouble Code Chart
P.13A-44). Then go to Step 22.
NO : Go to Step 4.

STEP 4. Using scan tool MB991958, read the ETACS

system diagnostic trouble code (DTC).
Using scan tool to read the ETACS system DTC (Refer to
GROUP 54A, ETACS, Troubleshooting −Diagnostic Function
P.54A-579).
Q: Is any DTC set?
YES : Repair the ETACS system (Refer to GROUP 54A,
ETACS, Troubleshooting −Diagnostic Trouble Code
Chart P.54A-582). Then go to Step 22.
NO : Go to Step 5.

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14-10 ENGINE COOLING
ENGINE COOLING DIAGNOSIS

STEP 5. Measure the voltage at ETACS-ECU connector

C-312.
(1) Disconnect the ETACS-ECU connector C-312, and
measure at front wiring harness connector side.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between terminal 2 and ground,
between terminal 8 and body ground, and between terminal
C-312 Harness connector:
Component side 9 and body ground.
OK: System voltage
(4) Turn the ignition switch to the "LOCK" (OFF) position.
(5) Connect the ETACS-ECU connector C-312.
Q: Is the check result normal?
YES : Go to Step 11.
AC708966 AB
NO : Go to Step 6.

STEP 6. Check the radiator fan relay connector A-35X,

condenser fan relay connector A-36X, fan control relay
connector A-37X, and ETACS-ECU connector C-312, for
loose, corroded or damaged terminals, or terminals
pushed back in the connector.
Refer to GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the connectors and terminals in good condition?
YES : Go to Step 7.
NO : Repair or replace damaged connectors. Then go to
Step 22.

STEP 7. Check the harness wire between fusible link

number 28 and condenser fan relay connector A-36X
terminal number 3, between fusible link number 28 and
condenser fan relay connector A-36X terminal number 4,
between condenser fan relay connector A-36X terminal
number 4 and fan control relay connector A-37X terminal
number 1, between fusible link number 29 and radiator fan
relay connector A-35X terminal number 3, for damage.
Fusible link number 29 Q: Is the harness wires in good condition?
Fusible link
number 28 YES : Go to Step 8.
NO : Repair the damaged harness wire. Then go to Step
22.

Engine compartment
Air cleaner assembly relay box AC708976 AB

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 ENGINE COOLING
ENGINE COOLING DIAGNOSIS
14-11

STEP 8. Check the harness wire between radiator fan relay

connector A-35X terminal number 1 and ETACS-ECU
connector C-312 terminal number 2, between condenser
fan relay connector A-36X terminal number 1 and
ETACS-ECU connector C-312 terminal number 8, between
fan control relay connector A-37X terminal number 3 and
ETACS-ECU connector C-312 terminal number 9, for
damage.
Q: Is the harness wires in good condition?
YES : Go to Step 9.
NO : Repair the damaged harness wire. Then go to Step
22.

STEP 9. Check the radiator fan relay, condenser fan relay

and fan control relay.
Refer to P.14-19.
Q: Is the relay in good condition?
YES : Go to Step 10.
NO : Replace the damaged relay. Then go to Step 22.

STEP 10. Check the fusible link number 28 and fusible link
number 29.
Q: Is the fusible link in good condition?
YES : An intermittent malfunction is suspected (Refer to
GROUP 00, How to use troubleshooting −How to
Cope with Intermittent Malfunction P.00-15).
NO : Replace the damaged fusible link. Then go to Step
22.

STEP 11. Check the radiator fan relay connector A-35X,

condenser fan relay connector A-36X, fan control relay
connector A-37X, radiator fan motor connector A-45 and
condenser fan motor connector A-47, for loose, corroded
or damaged terminals, or terminals pushed back in the
connector.
Refer to GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the connectors and terminals in good condition?
YES : Go to Step 12.
NO : Repair or replace damaged connectors. Then go to
Step 22.

STEP 12. Check the harness wire between fusible link

number 28 and condenser fan relay connector A-36X
terminal number 4, between fusible link number 29 and
radiator fan relay connector A-35X terminal number 4, for
damage.
Q: Is the harness wires in good condition?
YES : Go to Step 13.
NO : Repair the damaged harness wire. Then go to Step
22.

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14-12 ENGINE COOLING
ENGINE COOLING DIAGNOSIS

STEP 13. Check the harness wire between radiator fan

relay connector A-35X terminal number 2 and radiator fan
motor connector A-45 terminal number 1, between
condenser fan relay connector A-36X terminal number 2
and condenser fan motor connector A-47 terminal number
1, for damage.
Q: Is the harness wires in good condition?
YES : Go to Step 14.
NO : Repair the damaged harness wire. Then go to Step
22.

STEP 14. Check the harness wire between radiator fan

motor connector A-45 terminal number 2 and fan control
relay connector A-37X terminal number 2, between
condenser fan motor connector A-47 terminal number 2
and body ground, for damage.
Q: Is the harness wires in good condition?
YES : Go to Step 15.
NO : Repair the damaged harness wire. Then go to Step
22.

STEP 15. Check the harness wire between fan control relay
connector A-37X terminal number 4 and condenser fan
motor connector A-47 terminal number 1, between fan
control relay connector A-37X terminal number 5 and body
ground, for damage.
Q: Is the harness wires in good condition?
YES : Go to Step 16.
NO : Repair the damaged harness wire. Then go to Step
22.

STEP 16. Check the radiator fan relay, condenser fan relay
and fan control relay.
Refer to P.14-19.
Q: Is the relay in good condition?
YES : Go to Step 17.
NO : Replace the damaged relay. Then go to Step 22.

STEP 17. Check the radiator fan motor and condenser fan
motor.
• Check the output line for short or open circuit.
Refer to P.14-21.
Q: Is the fan motor in good condition?
YES : Go to Step 18.
NO : Replace the damaged fan motor (Refer to P.14-31).
Then go to Step 22.

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 ENGINE COOLING
ENGINE COOLING DIAGNOSIS
14-13

STEP 18. Using scan tool MB991958, read the ETACS

system diagnostic trouble code (DTC).
Using scan tool to read the ETACS system DTC (Refer to
GROUP 54A, ETACS, Troubleshooting −Diagnostic Function
P.54A-579).
Q: Is any DTC set?
YES : Replace the ETACS-ECU (Refer to GROUP 54A,
ETACS-ECU P.54A-676). Then go to Step 22.
NO : Go to Step 19.

STEP 19. Using scan tool MB991958, check the MFI system
actuator test.
Using scan tool to check the MFI system actuator test (Refer to
GROUP 13A, MFI Diagnosis −Diagnostic Function P.13A-9).
• Item 14: Cooling fan
(Refer to GROUP 13A, MFI Diagnosis −Actuator Test Refer-
ence Table P.13A-871)
Q: Is the check result normal?
YES : Go to Step 21.
NO : Go to Step 20.

STEP 20. Using scan tool MB991958, read the MFI system
diagnostic trouble code (DTC).
Using scan tool to read the MFI system DTC (Refer to GROUP
13A, MFI Diagnosis −Diagnostic Function P.13A-9).
Q: Is any DTC set?
YES : Replace the ECM (Refer to GROUP 13A, ECM
P.13A-920). Then go to Step 22.
NO : Go to Step 21.

STEP 21. Check the symptoms.

Q: Does the radiator fan and condenser fan operate
normal?
YES : An intermittent malfunction is suspected (Refer to
GROUP 00, How to use troubleshooting −How to
Cope with Intermittent Malfunction P.00-15).
NO : Replace the ECM (Refer to GROUP 13A, ECM
P.13A-920). Then go to Step 22.

STEP 22. Check the symptoms.

Q: Does the radiator fan and condenser fan operate
normal?
YES : The procedure is complete.
NO : Return to Step 1.

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14-14 ENGINE COOLING
SPECIAL TOOLS

SPECIAL TOOLS
M1141000601119

Tool Tool number and name Supersession Application

MB991958 MB991824-KIT CAUTION
a a: MB991824 NOTE: g: MB991826 For vehicles with CAN
b: MB991827 M.U.T.-III Trigger communication, use
c: MB991910 Harness is not M.U.T.-III main harness A
d: MB991911 necessary when to send simulated vehicle
MB991824
e: MB991914 pushing V.C.I. ENTER speed. If you connect
b f: MB991825 key. M.U.T.-III main harness B
g: MB991826 instead, the CAN
Scan tool (M.U.T.-III sub communication does not
assembly) function correctly.
a: Vehicle • Checking diagnostic
MB991827
communication trouble code (DTC).
c
interface (V. C. I.) • Checking actuator test.
b: M.U.T.-III USB cable
c: M.U.T.-III main
harness A (Vehicles
MB991910 with CAN
d communication
system)
Do not use d: M.U.T.-III main
harness B (Vehicles
without CAN
MB991911
communication
e system)
e: M.U.T.-III main
Do not use harness C (for Daimler
Chrysler models only)
MB991914 f: M.U.T.-III
measurement adapter
f
g: M.U.T.-III trigger
harness

MB991825

MB991826
MB991958

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 ENGINE COOLING
SPECIAL TOOLS
14-15
Tool Tool number and name Supersession Application
MB991223 General service tools Checking the continuity and
a
a: MB991219 measuring the voltage at the
b: MB991220 harness connector
b: MB991221
d: MB991222
b Harness set
a: Test harness
b: LED harness
c: LED harness adaptor
c
d: Probe

d
DO NOT USE
MB991223BF

MB992006 General service tool Continuity check and

Extra fine probe voltage measurement at
harness wire or connector
for loose, corroded or
damaged terminals, or
MB992006 AB
terminals pushed back in
the connector.
MB991871 General service tool Coolant refilling
LLC changer

MB991871

MB992042 MB992042-01 Engine coolant temperature

Water temp sensor sensor removal and
wrench installation

MB992042

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14-16 ENGINE COOLING
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
M1141001000849

WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
CAUTION
• Be sure to completely clean away any moisture from
the places checked.
• When the tester is taken out, be careful not to spill any
coolant.
• Be careful when installing and removing the tester and
when testing not to deform the filler neck of the radia-
tor.
1. Check that the coolant level is up to the filler neck. Install a
radiator tester and apply 160 kPa (23 psi) pressure, and
Cap adapter
then check for leakage from the radiator hose or
connections.
Adapter 2. If there is leakage, repair or replace the appropriate part.

ACX01844 AE

RADIATOR CAP OPENING PRESSURE CHECK

M1141001301003
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops
Cap adapter moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93 −123 kPa (14 −18 psi)
3. Replace the radiator cap if the reading does not remain at or
above the limit.

ACX01845AD

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 ENGINE COOLING
ON-VEHICLE SERVICE
14-17
ENGINE COOLANT CHANGE
M1141001201459

Required Special Tool:

• MB991871: LLC changer
1. Remove the engine room under cover front A (RH). (Refer to
GROUP 51, Under Cover P.51-16)
WARNING
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
2. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.
3. Remove the engine room under cover front B. (Refer to
GROUP 51, Under Cover P.51-16)
4. Remove the air cleaner intake hose. (Refer to GROUP 15,
Air Cleaner P.15-10)
5. Remove the turbocharger compressor bracket. (Refer to
GROUP 15, Exhaust Manifold and Turbocharger Assembly
P.15-16)
6. Disconnect the turbocharger water return hose and drain the
Turbo charger coolant in the water jacket.
air inlet fitting
7. Remove the radiator condenser tank and drain the coolant.
8. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
9. Connect the turbocharger water return hose.
10.Securely tighten the drain plug of the radiator.
11.Reinstall the radiator condenser tank.
Turbo charger
water return hose AC706501AC CAUTION
Do not use alcohol or methanol anti-freeze or any engine
coolants mixed with alcohol or methanol anti-freeze. The
use of an improper anti-freeze can cause corrosion of the
aluminum components.
12.By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the
range of 30 to 60%. Use special tool MB991871 to refill the
Air hose
engine coolant up to the top of the radiator port. A
MB991871
convenient mixture is a 50% water and 50% antifreeze
solution [freezing point: −31° C (−23.8 ° F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Quantity: 7.5 dm3 (7.9 quarts)
AC705466AC
NOTE: For how to use special tool (MB991871), refer to its
manufacturer’s instructions.
13.Tighten the radiator cap securely.
14.Remove the radiator condenser tank cap, and add the
engine coolant up to the "FULL" line.

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14-18 ENGINE COOLING
ON-VEHICLE SERVICE

15.Turn the A/C switch to OFF position to start the engine and
warm up until the cooling fan operates.
NOTE: This step opens the thermostat fully.
16.Rev the engine several times and then stop it. Check that
there are no coolant leaks.
17.Remove the radiator cap with the engine cool, and then refill
the engine coolant up to the top of the radiator port.
18.Tighten the radiator cap securely.
CAUTION
Do not overfill the radiator condenser tank.
19.Remove the radiator condenser tank cap, and add the
engine coolant up to the "FULL" line.
20.Install the turbocharger compressor bracket. (Refer to
GROUP 15, Exhaust Manifold and Turbocharger Assembly
P.15-16)
21.Install the air cleaner intake hose. (Refer to GROUP 15, Air
Cleaner P.15-10)
22.Remove the engine room under cover front B and engine
room under cover front A (RH). (Refer to GROUP 51, Under
Cover P.51-16)

WATER PUMP COOLANT LEAK CHECK

M1141008600080
If a residue of the coolant draining is found on the drain hole,
the vapor hole and the installation surface, check the water
pump leakage by following method.
1. Wipe off the residue of the coolant draining on the water
pump.
WARNING
Make sure that the coolant is cold when removing the
radiator cap.
2. Remove the radiator cap.
CAUTION
Do not pressures 100 kPa (15 psi) or more.
3. Install the radiator tester and pressures at 100 kPa (15 psi).
Cap adapter 4. Hold the pressurized state for 20 minutes, and check that
the water leakage from the drain hole, the vapor hole or the
installation surface of the water pump.
Adapter 5. Remove the radiator tester, and install the radiator cap.
6. Warm up the engine, let it idle for 20 minutes and stop it.
7. After stopping the engine, and check that the water leakage
from the drain hole, the vapor hole or the installation surface
of the water pump.
ACX01844 AE
8. If the water leakage is found in step 4 or 7, replace the water
pump. (Refer to P.14-25.)

ENGINE COOLANT CONCENTRATION TEST

M1141001101009
Refer to GROUP 00 −Recommended Lubricants and Lubricant
Capacities Table P.00-56.

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 ENGINE COOLING
ON-VEHICLE SERVICE
14-19
COOLING FAN RELAY CONTINUITY CHECK
M1141006201108
.

RADIATOR FAN RELAY CHECK

Battery voltage Terminal No. to Continuity test

be connected results
to tester
Not applied 2 −4 Open circuit
Connect Continuity (Less
terminal No. 3 than 2 ohms)
and battery (+)
AC705490
terminal.
Connect
Radiator fan relay terminal No. 1
and battery (−)
terminal.
4
2 2
1 3
4 3 1

AC707028AC

CONDENSER FAN RELAY CHECK

Battery voltage Terminal No. to Continuity test

be connected results
to tester
Not applied 4 −3 Open circuit
Connect Continuity (Less
terminal No.1 than 2 ohms)
and battery (+)
AC705490
terminal.
Connect
Condenser fan relay terminal No.2
and battery (−)
terminal.
4
2 3
1 3
4 1 2

AC707029AC

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14-20 ENGINE COOLING
ON-VEHICLE SERVICE

FAN CONTROL RELAY CHECK

Battery voltage Terminal No. to Continuity test

be connected results
to tester
Not applied 2 −4 Continuity (Less
than 2 ohms)
Not applied 2 −5 Open circuit
Connect Continuity (Less
AC705490 terminal No. 1 than 2 ohms)
and battery (+)
Fan control relay
terminal.
Connect
2
4 terminal No. 3
2 5 and battery (−)
1 4 3 terminal.
1 3
5

AC707030AC

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 ENGINE COOLING
ON-VEHICLE SERVICE
14-21
COOLING FAN MOTOR CHECK
M1141007600225
1. Disconnect the fan motor connector.
Condenser fan Radiator fan
motor connector motor connector

AC706502AC

2. Check that the fan motor runs when a positive battery

Condenser fan terminal is connected to the fan motor-side connector
motor connector terminal No.1, and terminal No.2 is grounded. Also check to
see that there is no abnormal sound emitted from the fan
motor at this time.
3. If the fan motor is defective, replace it (Refer to P.14-31).

AC706893AC

Radiator fan
motor connector

AC706894AC

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14-22 ENGINE COOLING
THERMOSTAT

THERMOSTAT
REMOVAL AND INSTALLATION
M1141002401713

Pre-removal operation Post-installation operation

• Engine Coolant Draining (Refer to P.14-17). • Air Cleaner Intake Hose Installation (Refer to GROUP 15,
• Engine Upper Cover Removal (Refer to GROUP 16, Igni- Air Cleaner P.15-10).
tion System −Ignition Coil P.16-39). • Engine Upper Cover Installation (Refer to GROUP 16,
• Air Cleaner Intake Hose Removal (Refer to GROUP 15, Ignition System −Ignition Coil P.16-39).
Air Cleaner P.15-10). • Engine Coolant Refilling (Refer to P.14-17).

5
4

3
10 ± 2 N·m
89 ± 17 in-lb

2
24 ± 3 N·m
18 ± 2 ft-lb
1

AC705834 AC

Removal steps Removal steps (Continued)

<<A>> >>B<< 1. Radiator lower hose connection 3. Harness bracket
2. Control wiring harness clamp 4. Cooling water inlet hose fitting
connection >>A<< 5. Thermostat

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 ENGINE COOLING
THERMOSTAT
14-23
REMOVAL SERVICE POINT
.

<<A>> RADIATOR LOWER HOSE DISCONNEC-

TION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.

Mating marks

AC200641AD

INSTALLATION SERVICE POINTS

.

>>A<< THERMOSTAT INSTALLATION

CAUTION
Make absolutely sure that no oil adheres to the rubber ring
of the thermostat. Also do not fold or scratch the rubber
ring during installation.
Install the thermostat so that the jiggle valve is facing straight
Jiggle valve
up. Be careful not to fold or scratch the rubber ring.

Rubber ring
AC000279 AD

>>B<< RADIATOR LOWER HOSE CONNECTION

1. Insert each hose as far as the projection of the water inlet
Projection fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Water inlet Mating

fitting marks
AC200642 AX

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14-24 ENGINE COOLING
THERMOSTAT

INSPECTION
M1141002501055
.

THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value: Valve opening temperature: 76.5 ±
1.5° C (170 ± 3° F)

ACX00400

2. Check that the amount of valve lift is at the standard value

when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is
fully closed, and use this measurement to compare the
valve height when the thermostat is fully open.
Standard value:
Full-opening temperature:90° C (194° F)
Valve lift
Amount of valve lift: 8.5 mm (0.33 inch) or more

ACX00401AD

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 ENGINE COOLING
WATER PUMP
14-25
WATER PUMP
REMOVAL AND INSTALLATION
M1141002701800

Pre-removal operation Post-installation operation

• Engine Coolant Draining (Refer to P.14-17). • Drive Belt Installation (Refer to GROUP 11A, Crankshaft
• Drive Belt Removal (Refer to GROUP 11A, Crankshaft Pulley P.11A-21).
Pulley P.11A-21). • Drive Belt Tension Check (Refer to GROUP 11A, Engine
• Engine Upper Cover Removal (Refer to GROUP 16, Igni- Adjustment −Drive Belt Tension Check and Adjustment
tion System −Ignition Coil P.16-39). P.11A-8).
• Strut Tower Bar Removal (Refer to GROUP 42A, Strut • Strut Tower Bar Installation (Refer to GROUP 42A, Strut
Tower Bar P.42A-15). Tower Bar P.42A-15).
• Engine Upper Cover Installation (Refer to GROUP 16,
Ignition System −Ignition Coil P.16-39).
• Engine Coolant Refilling (Refer to P.14-17).

24 ± 3 N·m
18 ± 2 ft-lb

N6

7N

24 ± 3 N·m
18 ± 2 ft-lb

1
24 ± 3 N·m
18 ± 2 ft-lb 5
9.0 ± 1.0 N·m
80 ± 9 in-lb
3 4
AC705835AC

Removal steps Removal steps (Continued)

1. Water pump pulley mounting bolts 4. Water pump pulley
2. Water pump inlet pipe mounting 5. Water pump
nuts 6. Cooling water line gasket
3. Water pump pulley and water 7. Water pump gasket
pump assembly

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14-26 ENGINE COOLING
WATER HOSE AND WATER PIPE

WATER HOSE AND WATER PIPE

REMOVAL AND INSTALLATION
M1141003302068

Pre-removal operation Post-installation operation

• Engine Coolant Draining (Refer to P.14-17). • Thermostat Installation (Refer to P.14-22).
• Engine Upper Cover Removal (Refer to GROUP 16, Igni- • Air Cleaner Assembly Installation (Refer to GROUP 15,
tion System −Ignition Coil P.16-39). Air Cleaner P.15-10).
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Engine Upper Cover Installation (Refer to GROUP 16,
Cleaner P.15-10). Ignition System −Ignition Coil P.16-39).
• Thermostat Removal (Refer to P.14-22). • Engine Coolant Refilling (Refer to P.14-17).

11 ± 1 N·m
98 ± 8 in-lb

22 11 ± 1 N·m 9
98 ± 8 in-lb
24 ± 3 N·m 24 ± 3 N·m
N 20 18 ± 2 ft-lb 18 ± 2 ft-lb
22
24 ± 3 N·m 19
18 ± 2 ft-lb
15 2
18
14 9.5 ± 1.5 N·m
84 ± 13 in-lb
3N
5.0 ± 1.0 N·m 12
45 ± 8 in-lb
21 N
8 6
10 ± 2 N·m 1
23 89 ± 17 in-lb
30 ± 9 N·m
22 ± 7 ft-lb
13 N
10
42 ± 7 N·m
11 31 ± 5 ft-lb

N 17 7
10 ± 2 N·m
5 16 89 ± 17 in-lb
10
24 ± 3 N·m
18 ± 2 ft-lb
24 ± 3 N·m
4 18 ± 2 ft-lb

AC705836AC

Thermostat case removal Thermostat case removal steps

steps (Continued)
<<A>> >>D<< 1. Radiator upper hose 11. Turbocharger water feed hose
2. Cooling water outlet hose fitting 12. Turbocharger water feed pipe
3. Cooling water outlet hose fitting 13. Gasket
gasket 14. Fuel return hose connection
4. Cooling water line hose <<B>> >>B<< 15. Fuel high-pressure hose
5. Cooling water line hose connection
6. Engine coolant temperature 16. Thermostat case
sensor connector connection 17. Thermostat case gasket
7. Heater hose connection Water pump inlet pipe removal
8. Ground cable connection steps
9. Control wiring harness 16. Thermostat case
connection 17. Thermostat case gasket
10. Harness bracket

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 ENGINE COOLING
WATER HOSE AND WATER PIPE
14-27
Water pump inlet pipe removal
steps (Continued)
• Turbocharger assembly (Refer to
GROUP 15, Exhaust Manifold
and Turbocharger Assembly
P.15-16)
18. Turbocharger water return hose
19. Water pump inlet pipe
20. Cooling water line gasket
>>C<< 21. O-ring
Engine coolant temperature
sensor removal steps
14. Fuel return hose connection
<<B>> >>B<< 15. Fuel high-pressure hose
connection
22. Emission control vacuum hose
and pipe assembly mounting
bolts
6. Engine coolant temperature
sensor connector
<<C>> >>A<< 23. Engine coolant temperature
sensor

Required Special Tool:

• MB992042: Water Temp Sensor Wrench

REMOVAL SERVICE POINTS

.

<<A>> RADIATOR UPPER HOSE DISCONNEC-

TION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.

Mating marks

AC200641AD

<<B>> FUEL HIGH-PRESSURE HOSE

DISCONNECTION
1. Follow the steps below to unlock the fuel high-pressure hose
Fuel high-pressure
hose
connector.

Retainer

Fuel delivery pipe

AC506790 AD

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14-28 ENGINE COOLING
WATER HOSE AND WATER PIPE

(1) Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide

Flat-tipped
screwdriver
and 1 mm (0.04inch) thick] into the retainer of the fuel
high-pressure hose connector.
Retainer
CAUTION
When pushing up the retainer of the fuel high-pressure
hose connector, pay attention to avoid damage to the
retainer.
Fuel high-pressure
Fuel delivery pipe hose
AC407430AG

Flat-tipped (2) Turn the flat-tipped screwdriver inserted into the retainer
screwdriver by 90 degrees to push up the retainer and unlock the fuel
Retainer high-pressure hose connector.
2. Remove the fuel high-pressure hose.

Fuel high-pressure
Fuel delivery pipe hose AC407429AF

<<C>> ENGINE COOLANT TEMPERATURE

SENSOR REMOVAL
Use special tool MB992042 to remove the engine coolant tem-
perature sensor.

MB992042
AC705545 AC

INSTALLATION SERVICE POINTS

.

>>A<< ENGINE COOLANT TEMPERATURE SEN-

SOR INSTALLATION
1. Apply sealant to the engine coolant temperature sensor
thread.
Specified sealant: Three bond 1324N or equivalent

AC103399AD

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 ENGINE COOLING
WATER HOSE AND WATER PIPE
14-29
2. Use special tool MB992042 to tighten the engine coolant
temperature sensor to the specified torque.
Tightening torque: 30 ± 9 N⋅ m (22 ± 7 ft-lb)

MB992042
AC705545 AC

>>B<< FUEL HIGH-PRESSURE HOSE

CONNECTION
CAUTION
• When pushing in the retainer of the fuel high-pressure
hose connector, pay attention to avoid damage to the
retainer.
• After the installation of the fuel high-pressure hose,
slightly pull the fuel high-pressure hose to check that it
is connected securely. At this time, also check that
there is approximately 1 mm (0.04inch) play.
1. Securely insert the fuel rail stopper into the fuel
Fuel high-pressure
high-pressure hose connector groove to install the fuel
hose
high-pressure hose to the fuel rail.
Stopper Retainer
2. Push in the retainer of the fuel high-pressure hose
connector to lock the fuel high-pressure hose and fuel rail.

Fuel delivery pipe

AC506794AC

>>C<< O-RING INSTALLATION

CAUTION
Avoid adhesion of engine oil or grease to the O-ring.
Thermostat case
Fit the O-ring in the water pump inlet pipe groove, wet the
O-ring circumference or the pipe mounting area inner wall, and
then insert the O-ring.

O-ring

Water pump
inlet pipe AC103007AF

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14-30 ENGINE COOLING
WATER HOSE AND WATER PIPE

>>D<< RADIATOR UPPER HOSE CONNECTION

1. Insert each hose as far as the projection of the water inlet
Projection fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Water inlet Mating

fitting marks
AC200642 AX

INSPECTION
M1141003400650

WATER PIPE AND HOSE CHECK

Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.

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 ENGINE COOLING
RADIATOR
14-31
RADIATOR
REMOVAL AND INSTALLATION
M1141001502141

Pre-removal operation Post-installation operation

• Engine Room Under Cover Front A and Engine Room • Charge Air Cooler Intake Hose B and Charge Air Cooler
Under Cover Center Removal (Refer to GROUP 51, Intake Pipe B Installation (Refer to GROUP 15, Charge
Under Cover P.51-16). Air Cooler P.15-15).
• Engine coolant Draining (Refer to P.14-17). • Engine coolant Refilling and Check (Refer to P.14-17).
• Charge Air Cooler Intake Hose B and Charge Air Cooler • Engine Room Under Cover Front A and Engine Room
Intake Pipe B Removal (Refer to GROUP 15, Charge Air Under Cover Center Installation (Refer to GROUP 51,
Cooler P.15-15). Under Cover P.51-16).

20
18 19
4 9.5 ± 3.5 N·m
3 84 ± 31 in-lb
6
22
7 5 21
4.0 ± 2.0 N·m
9.5 ± 3.5 N·m
36 ± 17 in-lb
84 ± 31 in-lb 15
15 3.4 ± 0.5 N·m 25
31 ± 4 in-lb
1
2N
4.4 ± 0.5 N·m 14
43 ± 4 in-lb 27
16
17 13

8 26

17
3.4 ± 0.5 N·m 13
31 ± 4 in-lb

9 4.4 ± 0.5 N·m 12

9.5 ± 3.5 N·m 23 43 ± 4 in-lb
84 ± 31 in-lb
10 11
24
AC710570 AB

Radiator removal steps Radiator removal steps

1. Radiator drain plug 12. Condenser fan motor connector
2. O-ring connection
3. Radiator cap • Front end upper bar (Refer to
4. Radiator condenser tank hose GROUP 42, Loose Panel
<<A>> >>A<< 5. Radiator upper hose P.42A-192)
6. Radiator cap assembly <<B>> 13. Bracket
<<A>> >>A<< 7. Radiator upper hose <<B>> 14. Fan, fan motor and fan shroud
<<A>> >>A<< 8. Radiator lower hose assembly
<<A>> >>A<< 9. Radiator lower hose 15. Support upper insulator
10. Radiator lower pipe assembly 16. Radiator assembly
11. Radiator fan motor connector 17. Support lower insulator
connection 18. Radiator condenser tank hose

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14-32 ENGINE COOLING
RADIATOR

Radiator removal steps

19. Radiator condenser tank hose
20. Radiator condenser tank
21. Radiator condenser tank pipe
22. Radiator condenser tank bracket
Fan shroud removal steps
4. Radiator condenser tank hose
<<A>> >>A<< 5. Radiator upper hose
6. Radiator cap assembly
11. Radiator fan motor connector
12. Condenser fan motor connector
• Front end upper bar (Refer to
GROUP 42, Loose Panel
P.42A-192)
<<B>> 13. Bracket
<<B>> 14. Fan, fan motor and fan shroud
assembly
23. Radiator fan
24. Radiator fan motor
25. Condenser fan
26. Condenser fan motor
27. Fan shroud

REMOVAL SERVICE POINTS

.

<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE REMOVAL
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.

Mating marks

AC200641AD

<<B>> BRACKET/FAN, FAN MOTOR AND FAN

SHROUD ASSEMBLY REMOVAL
Radiator assembly Remove the fan, fan motor, and fan shroud assembly from the
(3) radiator assembly with the following steps.
(2)
1. Remove the bracket.
(2)
(4) 2. Release the upper locks of the radiator assembly from the
fan, fan motor, and fan shroud assembly.
(4)
3. Slightly raise the fan, fan motor, and fan shroud assembly.
4. Release the lower locks of the radiator assembly from the
fan, fan motor, and fan shroud assembly. Then, remove the
Fan shroud assembly
fan, fan motor, and fan shroud assembly from the radiator
AC708620AC
assembly.

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 ENGINE COOLING
RADIATOR
14-33
INSTALLATION SERVICE POINT
.

>>A<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE INSTALLATION
1. Insert each hose as far as the projection of the water inlet
Projection fitting, water outlet fitting or radiator.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Radiator, water inlet Mating

fitting or water outlet marks
fitting AC200642 AY

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NOTES