SECTION 6B - ENGINE COOLING
Service Precaution
General Description
Diagnosis
Draining and Refilling Cooling System
Engine coolant change
Water Pump
Water Pump and Associated Parts
Removal
Inspection
Installation
Thermostat
Thermostat and Associated Parts
Removal
Inspection
Installation
Radiator
Radiator and Associated Parts
Removal
Inspection
Installation
Drive Belt and Cooling Fan
Drive Belt and Associated Parts
Inspection
Installation
Main Data and Specifications
SERVICE PRECAUTION
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS), REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
HOLDE N will call out those f asten ers th at requir e a
replacement after removal. HOLDEN will also call
out the fasteners that require thread lockers or
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints , greases,
or other corrosion inhibitors ) on threaded fast eners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
GENERAL DESCRIPTION
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The cooling system is a pressurized Engine Coolant
(EC) forced circulation type which consists of a water
pump, thermostat cooling fan, radiator and other
components. The automatic transmission fluid is cooled
by the EC in radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
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Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block
(7) Cylinde r Head
(8) Right Ban k
(9) Thrott le Body
(10) Cylinde r Bl ock
(11) Cy li nde r Head
(12) Left Bank
(13) Heater
Thermostat
The thermostat is a wax pellet type with a air hole(1)
and is installed in the thermostat housing.
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Radiator
The radiat or is a tu be ty pe wit h c or rugate d fi ns . In o rder
to raise the boiling point of the coolant, the radiator is
fitted with a ca p i n wh ich the va lv e is ope r ated at 88.2 ∼
117.6 kPa (12.8 ∼ 17.0 psi) pressure. (No oil cooler
provided for M/T)
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Anti Freeze Solution
• Relation between the mixing ratio and freezing
temperature of the Engine Coolant varies with the
ratio of anti–freeze solution in water. Proper mixing
ratio can be determined by referring to the chart.
Supplemental inhibitors or additives claiming to
increase cooling capability that have not been
specifically approved by HOLDEN are not
recommended for addition to the cooling system.
• Calculating mixing ratio
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NOTE: Antifreeze solution + Water = Total cooling
system capacity.
Total Cooling System Capacity
M/T 8.8Lit (2.32Us gal)
A/T 8.4Lit (2.22Us gal)
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• Mixing ratio
Check the specific gravity of engine coolant in the
coolin g s ystem tem per atu re range s fr om 0 °C to 50°C
using a suction type hydrometer, then determine the
density of the engine coolant by referring to the
table.Even in the areas where the atmospheric
temperature is higher than 0°C, be sure not to use
antifreeze solution at a mixing ratio lower than 20%
so that the inside of the engine may not be corroded.
NOTE: Even in the areas where the atmospheric
temperature is higher than 0°C, be sure not to use
antifree ze solution at a mixin g ratio lo wer than 20%
so that the inside of the engine may not be
corroded.
1. If antifreez e solu tion is us ed at a mi xing rat io high er
than 60%, the specific heat of the coolant falls and
the engine may be overheated. Moreover,
antifreeze performance drop and the coolant may
be frozen. The density of the solution must be
adjusted as occasion calls.
Antifreeze solution lower than 20% may not have
sufficient anticorrosive performance, and therefore,
please never fail to adjust as occasion demands
within the range of 20% to 60%.
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DIAGNOSIS
DRAINING AND REFILLING
COOLING SYSTEM
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the “MIN"
and “MAX" lines of reserve tank when the engine is
cold. If low, check for leakage and add EC up to the
“MAX" line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
ENGINE COOLANT CHANGE
1. To change engine coolant, make sure that the
engine is cool.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiator cap,
put a piece of thick cloth on the cap and loosen the
cap slowly to reduce the pressure when the coolant
has become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best result it is suggested that the
engine cooling system be flushed at least once a
year. It is advisable to flash the interior of the
cooling system including the radiator before using
anti-freeze (ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even minor
cracks.
HOLDEN recommends to use HOLDEN genuine
anti-freeze (ethylene-glycol based) or equivalent, for the
cooling system and not add any inhibitors or additives.
CAUTION: A failure to correctly fill the engine
cooling system in changing or topping up coolant
may s ometimes cause the coo lant to overflo w from
the filler neck even before the engine and radiator
are completely full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator.
And als o, the coolan t overflow will incr ease, making
Condition Possible cause Correcti on
Engine Cooling Trouble
Engine overheating Low Engine Coolant level Replenish
Incorrect fan installed Replace
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Damaged cy li nde r hea d gasket Replac e
Engine overcooling Faulty thermostat Replace
Engine slow to warm–up Faulty thermostat Replace
Thermo unit faulty Replace
it difficult to determine whether or not the system is
completely full.
5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.
6. After directly filling the radiator, fill the reservoir to
the maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiator cap,
put a piece of t hick cloth on the cap and loosen t he
cap slow ly t o r edu ce the pre ssu r e wh en t he co olan t
has become cooler.
8. Afte r tightenin g radiator cap, war m up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into
heater water system.
9. Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5-minute idling again and stop the engine.
10. W hen the eng ine has been coole d, ch eck fille r neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to “MAX"
line.
WATER PUMP
WATER PUMP AND ASSOCIATED PARTS
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REMOVAL
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to “Timing Belt" in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
INSPECTION
Make necessary repair and parts replacement if
extreme wear or damage is found during inspection.
Should any of the following problems occur, the entire
water pump assembly must be replaced:
• Crack in the water pump body
• EC leakage from the seal unit
• Play or abnormal noise in the bearing
• Cracks or corrosion in the impeller.
INSTALLATION
1. Install gasket, clean the mating surface of gasket
before installation.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N·m (2.5 kg·m/18 lb ft)
• Tightening order
The tightening order are in the illustrate.
NOTE: To prevent the oil leakage, apply the
LOCTITE 262 or an equivalent, to the arrow marked
fixing bolt thread.
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3. Id le pulley
• Install idl e pulley and ti ghten bolt to the specif ied
torque.
Legend
(1) Timing Belt
(2) Idle Pu lle y
(3) Water Pump Assembly
(4) Gasket
THERMOSTAT
THERMOSTAT AND ASSOCIATED PARTS
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REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
INSPECTION
Suspend the thermostat in a water–filled container
using thin wire. Place a thermometer next to the
thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
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Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5C ∼ 78.5°C
(166.1°F ∼ 173.3°F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90°C (194°F)
Make necessary repair and parts replacement if
extreme wear or damage is found during inspection.
INSTALLATION
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N·m (2.5 kg·m/18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.
Legend
(1) Thermostat Housing
(2) Thermostat
(3) O utle t Pipe
RADIATOR
RADIATOR AND ASSOCIATED PARTS
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REMOVAL
1. Disconnect battery ground cable.
2. Loosen a drain plug (2) to drain Engine Coolant.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
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5. Remove fan guide(1), clips (2) on both sides and the
bottom lock, then remove lower fan guide(3) with
fan shroud(4).
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6. Disconnect the reserve tank hose(4) from radiator.
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower
(4) Reserve Tank Hose
(5) Radiator Assembly
(6) Reserve Tank
7. Remove bracket.
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8. Lift up and remove the radiator assembly with hose,
taking care not to damage the radiator core with a
fan blade.
9. Remove rubber cushions on both sides at the
bottom.
INSPECTION
Radiator Cap
Measur e th e va lv e op eni ng pres s ure of th e pr es su riz ing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 88.3 ∼ 117.7
(12.8 ∼17.1)
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt
is fo und, or if the valv e seat cannot b e moved by hand ,
clean or replace the cap.
Valve opening vacuum kPa (psi) 1.96 ∼ 4.91 (0.28
∼ 0.71)
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Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 150
kPa (22 psi) with a cap tester:
• Leakage from the radiator
• Leakage from the coolant pump
• Leakage from the water hoses
• Check the rubber hoses for swelling.
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INSTALLATION
1. Install rubber cushions on both sides of radiator
bottom.
2. Install radiator assembly with hose, taking care not
to damage the radiator core with a fan blade.
3. Install bracket and support the radiator upper tank
with the bracket and secure the radiator.
4. Connect reserve tank hose (4).
5. Install lower fan guide (3).
6. Connect radiator inlet hose and outlet hose to the
engine.
7. Connect oil cooler hose (1) to automatic
transmission.
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8. Connect battery ground cable.
9. Pour engine co olant up to filler nec k of radiator, and
up to MAX mark of reserve tank.
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Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
1. Make sure that the engine is cool.
2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to “MAX"
line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiator cap,
put a piece of t hick cloth on the cap and loosen t he
cap slow ly t o r edu ce the pre ssu r e wh en t he co olan t
has become cooler.
5. After tightening radiator cap, warm up the
engine at about 2000 rpm. Set heater
adjustment to the highest temperature position,
and let the coolant circulate also into heater
water system.
6. Check to see the thermostat has opened
through the needle position of water
thermometer, conduct a 5–minute idling again
and stop the engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank
hose for leakage.
8. Pour coolant into reservoir tank up tp “MAX"
line.
DRIVE BELT AND COOLING FAN
DRIVE BELT AND ASSOCIATED PARTS
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The drive belt adjustment is not required as automatic
drive belt tensioner is equipped.
INSPECTION
Check drive belt for wear or damage, and replace with a
new one as necessary.
INSTALLATION
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Torque : 22 N·m (2.2 kg·m/16 lb ft) for fan pulley
and fan bracke t.
Torque : 10 N·m (1.0 kg·m/87 lb in) for fan and
clutch ass embly.
Legend
(1) Crankshaft Pul ley
(2) Generator
(3) Power Steering Pump
(4) Water Pump and Cooling Fan Pulley
(5) Idle Pulley
(6) Tension Pulley
(7) Dr iv e Bel t
MAIN DATA AND SPECIFICATIONS
General Specifications
Torque Specifications
N·m (kg·m/lbft)
E06R100007
M/T A/T
Cooling sy st em Engine coo la nt forced circulat ion
Radiator Tube type corrugated (2 tube in row)
Heat radiation capacity 70,000 kcal/h 77,800 kcal/h
Heat radiation area 9.74m2 (104.8ft2) 11.74m2 (126.4ft2)
Radiator front area 0.263m2 (2.83ft2)
Radiator dry weight 42N (9.4lb) 45N (10.1lb)
Radiator cap valve opening pressure 93.3 ∼ 122.7kpa (13.5 ∼ 17.8psi)
Engine coolant capacity 2.5lit (2.6U.Sq.t.) 2.4lit (2.5U.Sq.t.)
Engine coolant pump Centrifugal impeller type
Delivery 300 (317) or more
Pump speed 5000 ± 50rpm
Thermostat W ax pellet type with air hole
Valve opening temperature 74.5 ∼ 78.5°C (166.1 ∼ 173.3°F)
Engine coolant total capacity 10.5lit (11.10U.Sqt) 10.4lit (10.99U.Sqt)