SECTION 6B1 - ENGINE COOLING - 6VE1

Service Precaution

General Description

Diagnosis

Draining and Refilling Cooling System

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

Special Tool

Service Precaution

WARNING: IF SO EQUIPPED WITH 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.

HOLDEN will call out those fasteners that require 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 fasteners

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.

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General Description

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The cooling system is a pressurised 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 centrifugal impeller type pump is belt driven.

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Legend

(1) Water Pump

(2) Thermostat

(3) Radiator

(4) Reserve Tank

(5) Cooling Fan

(6) Cylinder Block

(7) Cylinder Head

(8) Right Bank

(9) Throttle Body

(10) Cylinder Block

(11) Cylinder 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 radiator is a tube type with corrugated fins. In order

to raise the boiling point of the coolant, the radiator is

fitted with a cap in which the valve is operated at 88.2 ~

117.6 kPa (12.8 ~ 17.0 psi) pressure. (No oil cooler

provided for M/T)

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Coolant Specification

• 50% water and 50% coolant conforming to Holden

HN2217 specification

•Capacity:

9.1 litres — 6VE1 (Automatic Transmission)

9.2 litres — 6VE1 (Manual Transmission)

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Diagnosis

Engine Cooling Trouble

Condition Possible Cause Correction

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 cylinder head gasket Replace

Engine overcooling Faulty thermostat Replace

Engine slow to warm–up Faulty thermostat Replace

Thermo unit faulty Replace

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.

1. Completely drain the cooling system by opening the

drain plug (2) at the bottom of the radiator.

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2. Remove the radiator cap.

WARNING: To avoid the danger of being burned, do

not remove the cap while the engine and radiator

are still hot. Scalding fluid and steam can be blown

out under pressure.

3. Disconnect all hoses from the EC reserve tank.

Scrub and clean the inside of the reserve tank with

soap and water. Flush it well with clean water, then

drain it. Install the reserve tank and hoses.

4. Refill the cooling system with 50% water and 50%

coolant conforming to Holden HN2217 specification

5. Fill the radiator to the base of the filler neck.

Fill the EC reserve tank to “MAX” line when the

engine is cold.

6. Block the drive wheels and firmly apply the parking

brake. Shift an automatic transmission to “P” (Park)

or a manual transmission to neutral.

7. Remove the radiator cap. Start the engine and warm

it up at 2,500 ~ 3,000 rpm for about 30 minutes.

8. When the air comes out from the radiator filler neck

and the EC level has gone down, replenish with the

EC. Repeat this procedure until the EC level does

not go down. Then stop the engine and install the

radiator cap. Let the engine cool down.

9. After the engine has cooled, replenish with EC up to

the “MAX” line of the reserve tank.

10. Start the engine. With the engine running at 3,000

rpm, make sure there is no running water sound

from the heater core (behind the center console).

11. If the running water sound is heard, repeat steps 8

to 10.

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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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Legend

(1) Timing Belt

(2) Idle Pulley

(3) Water Pump Assembly

(4) Gasket

3. Idle pulley

• Install idle pulley and tighten bolt to the specified

torque.

Torque: 52 N·m (5.3 Kg·m/38 lb ft)

4. Drive belt

• Install drive belt. Refer to drive belt installation

diagram in this section.

5. Connect radiator inlet hose and replenish EC.

6. Connect battery ground cable.

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) Outlet Pipe

Radiator

Radiator and Associated Parts

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Removal

1. Disconnect battery ground cable.

2. Loosen a drain plug(2) to drain EC.

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(3) on both sides and the

bottom lock, then remove lower fan guide(3) with

fan shroud(4).

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Legend

(1) Oil Cooler Hose For Automatic Transmission

(2) Radiator Hose

(3) Fan Guide, Lower

(4) Reserve Tank Hose

(5) Bracket

(6) Radiator Assembly

(7) Reserve Tank

6. Disconnect the reserve tank hose(4) from radiator.

7. Remove bracket(5).

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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

Measure the valve opening pressure of the pressurizing

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)

Cap tester: 5–8840–0277–0

Adapter: 5–8840–2603–0

Check the condition of the vacuum valve in the center of

the valve seat side of the cap. If considerable rust or dirt

is found, or if the valve seat cannot be 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 196

kPa (28.5 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.

Cap tester: 5–8840–0277–0

Adapter: 5–8840–2603–0

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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 (6) and support the radiator upper

tank with the bracket (5) 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 coolant up to filler neck 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 thick cloth on the cap and loosen the

cap slowly to reduce the pressure when the coolant

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.

Legend

(1) Crankshaft Pulley

(2) Generator

(3) Power Steering Pump

(4) Water Pump and Cooling Fan Pulley

(5) Idle Pulley

(6) Tension Pulley

(7) Drive Belt

Techline

Installation

The stud with a blue marking (Figure 1) on the fan

clutch bracket must be aligned with the hole with the

yellow marking on the fan clutch assembly (Figure 2) to

insure proper balance.

NOTE: In some instances the blue alignment marking

may be found on the bracket.

An out of balance clutch assembly and bracket can add

stress, which may result in bracket breakage.

NOTE: When reinstalling cooling fan assembly, tighten

bolts/nuts to the specified torque.

• Fan pulley and fan bracket (Torque 16 lb ft)

• Fan and clutch assembly (Torque 66.4 lb in)

NOTE: For correct component assembly orientation

Install cooling fan assembly and tighten bolts/nuts to the

specified torque.

Torque : 22 Nm (16 lb ft) for fan pulley and fan

bracket.

Torque : 10 Nm (88.5 lb in) for fan and clutch

assembly.

NOTE: A single serpentine accessory drive belt was

introduced for the MY1998 6VE1-W engine. As a result,

the cooling fan direction-of-rotation (DOR) of the on

these engines is opposite to that of the MY1992-

MY1997 6VD1-S.

Therefore, incorrect installation of a fan may cause the

air for cooling to flow in the opposite direction, this

resulting in the poor performance of the air-conditioner

and a rise temperature in engine cooling water.

figure 1

figure 2

Main Data and Specifications

General Specifications

Torque Specifications

N·m (Kg·m/lbft)

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M/T A/T

Cooling system Engine coolant forced circulation

Radiator (1 tube in row) Tube type corrugated (2 tube in row)

Heat radiation capacity 68,000 kcal/h 77,000 kcal/h

Heat radiation area 9.445m (0.878ft ) 11.21m (1.04ft )

Radiator front area 0.302m (0.028ft )

Radiator dry weight 39N (8.8lb) 44N (9.9lb)

Radiator cap valve opening pressure 93.3 ~ 122.7kpa (13.5 ~ 17.8psi)

Engine coolant capacity 2.5lit (2.6U.S q.t.) 2.4lit (2.5U.S q.t.)

Engine coolant pump Centrifugal impeller type

Delivery 300 (317) or more

Pump speed 5000 ± 50 rpm

Thermostat Wax pellet type with air hole

Valve opening temperature 74.5 ~ 78.5°C (166.1 ~ 173.3°F)

Engine coolant total capacity 10.4lit (11.0U.S qt) 10.5lit (11.1U.S qt)

Special Tool

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–0277–0

(J–24460–01)

Tester; radiator cap

5–8840–2603–0

(J–33984–A)

Adapter; radiator cap