SECTION 6B3 - ENGINE COOLING -

GEN III V8 ENGINE

CAUTION:

This vehicle w ill be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either seat

belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front passenger's air

bags or seat belt pre-tensioners, driver’s and front passenger’s air bag and left and right hand side air bags.

Refer to SAFETY PRECAUTIONS, Section 12M, Supplemental Restraint System of the VT Series I Service

Information before performing any service operation on, or around any SRS components, the steering

mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could result in SRS deployment,

resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service

Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as detailed

in 4. DIAGNOSIS, ABS or ABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC, in either of the VT

Series I Service Information (V6) or the VT Series II Service Information (GEN III V8).

1. GENERAL INFORMATION

The c ooling system f or VT Series II Models with the GEN III V8 engine, consists of two, two-speed electr ic cooling f ans

mounted behind the radiator. Fan operation is dependent on engine coolant temperature, vehicle speed, A/C request

(where fitted) and A/C system pressure. Refer to Section 6C3 POWERTRAIN MANAGEMENT - GEN III V8 ENGINE

of the VT Series II Service Information.

Techline

1.1 GENERAL DESCRIPTION

The radiator (1) is of the crossflow design and

consists of an aluminium core with plastic side

tanks attached to each end of the core.

For vehicles with automatic transmission,

transmission oil coolers are located in both the left

hand and right hand side tanks.

Pegs are attached to the lower frame and the upper

area of each side tank. These pegs are used to

support the radiator in four rubber mounts. The

assembly is held in position by two spring clips at

the upper mounting locations.

The radiator core side tanks or transmission oil

cooler CANNOT be replaced separately. If there is

a fault with any of these components, the radiator

assembly (1) must be replaced. Small core repairs

can be made using an Aluminised Silicon based

- Radiator Repair Procedure, in this Section.

The cooling fan and electric motor assemblies (2)

are supported in a polypropylene mounting bracket

that also forms the radiator shroud (3). The

mounting bracket and fan shroud (3) are moulded

as a one piece assembly and is attached to the

radiator side tanks.

The PCM determines operation of the two, two-

speed engine cooling fans based on A/C request,

A/C system pressure (where fitted), engine coolant

temperature and vehicle speed signal inputs. For

details of the engine cooling fan operation, see

Section 6C3 POWERTRAIN MANAGEMENT -

GEN III V8 ENGINE, of the VT Series II Service

Information.

Figure 6B3-1

The c oolant pump (1) is mounted to the front of the

cylinder block and is driven by the serpentine drive

belt (2). Coolant passes through the engine from

the coolant pump inlet, and exits via the coolant

outlet, located at the top of the coolant pump

housing.

Figure 6B3-2

liquid repair agent, refer to 2.16 RADIATOR

The coolant outlet (1) is located at the top of the

coolant pump housing.

The thermostat is also located in the coolant pum p

housing, at the coolant inlet fitting (2).

Figure 6B3-3

A wax pellet type thermostat is used in the coolant

inlet passage to control the flow of coolant,

providing fast engine warm up and regulating

coolant temperature.

The wax pellet or power element in the therm ostat,

expands when heated and contracts when cooled.

The wax pellet is located inside the brass body (1)

that forms an integral part of the flow control valve

(2). When the pellet is heated, pressure is exerted

against a piston and pin (3) that reacts against the

thermostat housing (4).

With cold coolant (view ‘A’), the flow control valve

(2) remains closed, preventing coolant flow from

the radiator to enter but coolant in the engine still

circulates, with hotter coolant from the cylinder

heads being directed through the end of the

thermostat, flowing over the wax pellet body.

This results in warming of the wax pellet at the

sam e rate as the temper ature rise of the coolant in

the engine.

Figure 6B3-4

As the coolant warms up (view ‘B’), the wax pellet

expands, causing the brass body (1) to move back

into the smaller spring cavity due to the reaction of

the piston and pin (3) against the thermostat

housing (4). As the body (1) moves back (bold

arrow), less of the engine bypass coolant flows

over the body, warm ing the wax inside but the flow

control valve (2) now opens, allowing coolant to

flow from the radiator and into the engine.

The rate that the control valve (2) opens, is

balanced between the force exerted by the

expanding wax and the c ombined f orce exterted by

the two springs (5 and 6).

This controlled flow of coolant during a cold start

and initial warming of the engine, provides a

controlled warming cycle, necessary to control

exhaust emissions during this critical period.

Figure 6B3-5

A screw-on pressure cap (1), fitted to the coolant

surge tank, causes the cooling system to operate at

higher than atmospheric pressure. This higher

pressure, raises the boiling point of the coolant,

resulting in increased engine cooling efficiency.

The pressure cap (1) contains a pressure valve (2)

and a vacuum (atmospheric) valve (3). The

pressure valve is held against its seat (4) by a

spring (5) which determines the maximum

operating pressure of the cooling system (100 kPa

for the G EN III V8 engine). The vacuum valve (3) is

held against its seat by a light spring (6). The

vacuum created during coolant cool down over-

comes the vacuum valve spring force and opens

the valve (3), preventing the radiator hoses from

collapsing.

The coolant is maintained at the ideal level by the

pressure cap and the coolant surge tank, resulting

in an increased cooling efficiency.

Figure 6B3-6

Located on the left hand inner fender skirt behind

the air cleaner as shown in Figure 6B3-7, the

coolant surge tank (1) is connected to the engine

cooling s ystem by a pressure hos e from the heater

connection at the coolant pump (2) and a vapour

hose (3) from the left hand radiator side tank.

As the engine temperature rises, the coolant heats

and expands. The fluid displaced by expansion

flows into the coolant surge tank. W hen the engine

is turned off, the coolant contracts as it cools and

the pressure in the surge tank returns to

atmospheric, by the unseating of the vacuum

valvein the screw-on pressure cap (4), if necessary.

Coolant level should be m aintained at the indicated

point on the side of the surge tank, when the

engine is cold, by sighting the level externally.

The cooling system is designed to use DEX-

COOL® coolant (to GM 6277M Specification) in a

concentration level of 50% DEX-COOL® to 50%

good quality, clean water. This mixture is required

to maintain the integrity of the cooling system, and

to prevent oxidation occurring within the engine.

CAUTION: Because the surge tank is

pressurised, the t emperature of t he coolant can

be considerably higher than 100°

°°

° C, without

boiling. Removing the screw-on pressure cap

when the engine is hot (high cooling system

pressure), will cause the coolant solution to

boil instantaneously.

This will result in the coolant spewing out over

the engine, fenders and the person removing

the cap, resulting in possible serious scalding.

Figure 6B3-7

Any vapour that develops in the engine ( or air when

the cooling system is being filled), is routed back to

the coolant surge tank, through a vapor vent pipe

fastened to the cylinder heads in four places.

Vapour then flows via hoses, through the throttle

body, to the left hand radiator side tank. Another

hose then connects the left hand radiator side tank

with the coolant surge tank, thereby directing

vapour/air to that point.

Figure 6B3-8

Air baf f les and s ide c hutes are fitted to the front end of the vehicle to direc t and promote air flow through the radiator to

provide maximum cooling.

The purpos e of the air baff les is to create a low pressur e area behind the radiator and a high pressure area in front of

the radiator, when the vehicle is at speed.

This enables additional air flow through the radiator core to maintain the desired engine cooling.

The air baff les or side chutes should never be removed unless for service work . If either the air baf fles or side chutes

are damaged, this will reduce the cooling system efficiency, and therefore they must be replaced.

1. Left Hand Side Air Chute 3. Lower Front Air Chute Baffle 5. Lower Rear Air Chute Baffle

2. Right Hand Side Air Chute 4. Fastener (4 places) 6. Screw (2 places)

Figure 6B3-9

An oil pan under- tray (1) also f orm s an integral part

of the air f low system ar ound the GEN III V8 engine

and must always be reinstalled after removal for

service operations, such as engine oil draining and

oil filter replacement.

NOTE: This tray is not designed as an oil pan

stone guard.

Figure 6B3-10

An upper radiator shroud is fitted between the

upper radiator support panel and the radiator

assembly, to minimise the recirculation of hot air

from the rear of the radiator back over the core.

Figure 6B3-11

A coolant temper ature sens or (1) is m ounted in the

front of the left hand cylinder head.

The c oolant temperatur e sensor generates a signal

which is used by the Powertrain Control Module

(PCM) for calculation of the various powertrain

management functions. This information is

transmitted to other control modules, e.g.

Instrum ents for the temperature gauge f unction, on

the serial data bus.

Figure 6B3-12

2. SERVICE OPERATIONS

2.1 SERVICE NOTES

CAUTION: TO AVOID SERIOUS PERSONAL INJURY, NEVER REMOVE THE SCREW-ON SURGE TANK CAP

WHEN T HE ENGINE IS HOT , EVEN IF THE CO OLING SYST EM SHOULD REQUIRE FILL ING. SUDDEN RELEASE

OF COOLING SYSTEM PRESSURE IS VERY DANGEROUS.

Before r emoving the surge tank cap, allow the engine to cool, then place a shop rag over the surge tank cap and then

slowly turn the cap anti-clockwise, to loosen. DO NOT SPIN THE CAP OFF! If there is any residual pressure in the

cooling system, it can then be released into the dam under the cap and out through the drain hose onto the ground.

When all pressure has been dispersed in this way, the cap can then be fully removed.

The vehicle is fitted with twin radiator electric cooling fans. When working around the engine compartment with the

engine running or with the ignition on, keep clear of the fan as it may start operating without warning.

The cooling system requires little care except for maintaining the coolant to the correct level in the coolant surge tank

and periodic servicing at the time or distance intervals as outlined in the Owner's Handbook.

Periodic servicing includes:

1. Checking coolant level, refer to 2.3 DRAINING AND FILLING COOLING SYSTEM this Section.

2. Checking coolant concentration, refer to 2.2 COOLANT MAINTENANCE - Testing Coolant Concentration this

Section.

3. Pressure test cooling system and radiator cap, refer to 2.8 PRESSURE TESTING in this Section.

4. Check/tighten hose clam ps and inspect all hos es, ref er to 2.4 COOLANT HOSES in this Sec tion. Replac e hos es if

swollen or deteriorated.

CAUTION: ALWAYS WEAR PROTECTIVE SAFETY GLASSES WHEN WORKING WITH SPRING TYPE HOSE

CLAMPS. FAILURE TO DO SO COULD RESULT IN EYE INJURY.

5. Clean out cooling system, ref er 2.5 CL EANING COOLING SY ST EM, in this Sec tion and re f ill cooling system, ref er

to 2.3 DRAINING AND FILLING COOLING SYSTEM in this Section.

2.2 COOLANT MAINTENANCE

The cooling system is designed to use a specific

coolant (a mixture of DEX-COOL® coolant to GM

Specification 6277M coolant additive and water),

rather than plain water.

The use of this orange coloured coolant additive also

raises the boiling point and increases the cooling

system efficiency. For this reason, it is of the utmost

impor tance that the cor rect c oncentra tion level of DEX-

COOL® is maintained in the cooling system.

Addition of plain water into the cooling system when

'topping-up' may dilute the coolant mixture to a point

where the specific properties of

DEX-COOL® become ineffective.

The coolant should comprise of a mixture 50% DEX-

COOL® (GM Specification 6277M) with 50% clean,

good quality water.

NOTE: Do not mix different types of antifreeze or

corrosion inhibitors as they may be incompatible. If a

different type has been used in the cooling system,

flush the system with clean water, refer to

2.5 CLEANING COOLING SYSTEM in this Section

and refill the cooling system with the correct coolant,

refer to 2.3 DRAINING AND FILLING COOLING

SYSTEM in this Section.

TOPPING UP THE COOLING SYSTEM

The coolant level can be externally checked at the

coolant surge tank.

Pre-mixed coolant (50% DEX-COOL® to GM

Specification 6277M with 50% clean, good quality

water) may be added as necessary to bring the

level shown on the coolant surge tank but only

when the engine is cold.

Figure 6B3-13

TESTING COOLANT CONCENTRATION

To ensure the specified ethylene glycol concentration

is maintained in the engine coolant, the coolant

concentration m ust be checked at the time or distance

intervals outlined in the Owner's Handbook.

While a number of coolant concentration measuring

devices are available, the two preferred types are as

described. Check coolant concentration as follows:

METHOD 1 - RERACTOMETER

NOTE 1: Coolant tester, Tool No. J 26568,

automatically compensates for temperature.

NOTE 2: Ensure that the eyepiece of the tester is free

of coolant before looking through it.

NOTE 3: Before each use, swing back the plastic

cover at the slanted end of the coolant tester, exposing

the measuring window and the bottom of the plastic

cover. Carefully wipe the measuring window dry with a

tissue or clean, soft cloth. Close the plastic cover.

1. Check the calibration of the coolant tester as

follows:

a. Place a few drops of distilled water (between

21 - 29° C) onto the meas uring window, then

close the plastic cover.

b. Point the tester toward any light source, look

into the eyepiece and check that the

indicated reading is zero. If not, then re-

calibrate the tester as detailed in the next

service operation - Calibrating the Tester.

2. Release the tip of the bulb pump from under

the refractometer body. It is not necessary to

remove the complete pump from the tool.

3. Carefully remove the screw-on coolant surge

tank cap, refer to 2.1 SERVICE NOTES for

important safety items.

4. Insert the tube of the pump into the coolant,

then press the bulb to obtain a sample.

5. Bend the tube around and insert the end into

the cover plate opening.

6. Press the pum p bulb to deposit a f ew drops of

coolant onto the measuring surface. Do not

open the plastic cover when taking readings,

as water evaporation will change the reading

obtained.

Figure 6B3-14

7. Point the coolant tester toward any light

source, looking into the eyepiece.

a. The coolant protection reading is at the

point where the dividing line between the

light and dark, crosses the scale.

b. The scale for ethylene glycol (bold arrow)

is the reference scale for DEX-COOL®

coolant.

NOTE: The temperature scale is reversed from

that of a conventional thermometer. Below zero

readings are on the upper half of the scale.

8. A reading between -30 and -52° C

(corresponding to a coolant concentration

between 45 - 60%), is satis factor y for the GEN

III V8 engine cooling system.

Figure 6B3-15

NOTE: If the reading is not clear, then properly

clean and dry the measuring surface, then conduct

another test. Also ensure that there is sufficient

fluid on the measuring prism.

9. If the reading shows that the concentration

level of the coolant is inadequate, r ef er to the

previous table to determine the amount of

DEX-COOL® that needs to be added to the

surge tank.

10. Start and run the engine until normal

operating temperature is reached, to allow

the added coolant to be distributed

throughout the engine cooling system.

Figure 6B3-16

HYDRO-METER

READING % LITRES OF DEX-COOL® TO BE ADDED

0 6.0

5 5.7

10 5.3

15 4.9

20 4.5

25 4.0

30 3.4

35 2.8

40 2.0

45 1.1

50 0

Calibrating the Tester

While the coolant tester calibration is checked at

manufacture, if the calibration check detailed in step 1

of this m ethod s hows that the instrum ent is not reading

correctly, then conduct the following re-calibration

procedure;

1. Remove the sealant covering the adjustment

screw on the underneath of the tester.

2. With a distilled water sample on the measuring

surface, carefully adjust the screw until a zero

reading is obtained.

NOTE: DO NOT completely remove the screw.

3. After re-calibration, reseal the screw with a small

amount of silicone sealant.

METHOD 2: - HYDROMETER

1. Cooling system should be at or close to ambient

temperature.

2. Carefully remove the screw-on pressure cap

from the surge tank and, while holding the

rubber bulb squeezed, insert nozzle of coolant

tester hydrometer, T ool No. AU435 into coolant.

Releasing the rubber bulb will then draw

sufficient coolant into the tester to float

hydrometer bulb freely.

3. Hold tester at eye level and read scale on

hydrometer bulb at coolant level.

The reading shows the percentage of ethylene

glycol antifreeze contained in the engine

coolant.

4. The hydrometer reading should show 50% if the

coolant concentration is correct.

If a reading of less than 50% is achieved, the

cooling system requires topping up with DEX-

COOL® ethylene glycol coolant additive to GM

Specification 6277M.

Refer to the chart shown for the previous

method to determine how much DEX-COOL®

ethylene glycol antifreeze is required to add to

the cooling system to bring the coolant to the

specified concentration.

5. Drain sufficient quantity of coolant from cooling

system to allow top-up with DEX-COOL®

coolant additive, then add the required amount.

Install screw-on pressure cap.

6. Start and run the engine until normal operating

temperature is reached, to allow the added

coolant to be distributed throughout the engine

cooling system.

Figure 6B3-17

NOTE: As an alternative to using the refractometer or

hydrometer, An anti-freeze hydrometer is available

from Snap-on® Tools Australia Pty Ltd under the part

number, EZRS102AUS.

2.3 DRAINING AND FILLING COOLING SYSTEM

DRAINING

CAUTION: To avoid the posibility of scalding, it is

recommended that this operation is only carried

out when the engine is cold.

The recommended method of draining the GEN III V8

engine cooling system, is to remove the screw-on

pressure cap from the surge tank, then remove the

hose clamp from the radiator hose at the lower left

hand radiator side tank, draining the cooling system

contents into a suitable clean container.

FILLING

As the GEN III V8 engine has a vapour pipe attached

to to both cylinder heads, that releases any air in the

cooling system, no special bleeding procedure is

required, apart from the following simple points:

1. Set the heater control to maximum.

2. Reinstall hose to radiator lower outlet on the left

hand side tank and tighten hose clamp.

3. Mix 6 litres of DEX-COOL ethylene glycol

antifreeze/inhibitor (to GM Specification 6277M)

with 6 litres of clean, good quality water.

NOTE 1: Do not mix different types of antifreeze or

corrosion inhibitors as they may be incompatible. If a

different type has been used in the cooling system,

flush the system with clean water, refer to

2.4 CLEANING COOLING SYSTEM in this Section.

NOTE 2: When using DEX-COOL® ethylene glycol

antifreeze/inhibitor (to GM Specification 6277M)

DO NOT add a pack of cooling system pellets to

the cooling system.

4. Carefully fill the cooling system by pouring the

pre-mixed coolant into the surge tank opening

until the level is correct.

5. Pressure test cooling system, refer to

2.8 PRESSURE TESTING in this Section.

6. Reinstall the screw-on pressure cap to the

resevoir.

7. Start and r un the engine until normal operating

temperature is reached, at which time the

added quantity of DEX-COOL® coolant

additive will have dispersed through the

engine’s cooling system.

Figure 6B3-18

Techline

2.4 COOLANT HOSES

Coolant hoses are installed as shown in the following illustrations.

Hose connections should be thoroughly cleaned before installing any new hose.

NOTE: Because of the production m ethod of inst alling the spring type hose clam ps, access to the clamp ends m ay not

be poss ible. Partic ularly for the c lam ps s ecuring the hos es to the lower bridging piece of the coolant intak e and coolant

surge tank hoses, it may be necessary to remove the complete hose assembly from the vehicle.

After any part of the cooling system is disturbed, the cooling system must always be refilled with the correct

concentration of coolant, r efer to 2.3 DRAINING AND FILLING COOLING SYST EM and pressure tes t cooling system,

refer to 2.8 PRESSURE TESTING in this Section.

1. Hoses – Heater 5. Hose - Radiator Upper 9. Hose - V apour t o Radi ator

2. Hose - To Coolant Surge Tank 1 of 2 6. Bridging Pi pe - Radi ator Hoses 10. Hose - Vapour to Surge tank

3. Hose - Radiator Lower 1 of 2 7. Hose - Radiator Lower 2 of 2 11. Pump Coolant

4. Radiator 8. Hose - To Coolant S urge Tank 2 of 2 12. Housing - Thermostat

Figure 6B3-19 - Cooling System Hose Layout - GEN III V8 Engine

1. Clamps - Hose 4. Pipes – B rake 7. Valve - Coolant Fl ow Control

2. Hose - HVAC Vacuum 5. Hoses Heat er Tap t o Dash Panel 8. Clip - Coolant Fl ow Control V al ve

3. Booster - B rake 6. Hose - To Coolant S urge Tank 1 of 2

Figure 6B3-20 - Heater Hose Arrangement - GEN III V8 Engine

2.5 CLEANING COOLING SYSTEM

NOTE: Before carrying out reverse flushing

procedures , it is rec om m ended that a cleaning solution

be used to loosen scale and corrosion. Use Holden

radiator cleaner, P/N M39304, following the

instructions on the container.

COOLING SYSTEM REVERSE FLUSH

CAUTION: This operation should only be

carried out when the engine and radiator are at

ambient temperature.

When using specialised cooling system flushing

equipment, only connect as recommended by the

manufacturer.

1. Remove the engine dress cover (1) after

removing the four decorative retaining nuts (2).

Figure 6B3-21

RADIA T OR:

1. Place suitable drain tray beneath vehicle.

2. Remove the screw-on pressure cap from the

coolant surge tank, taking care to release any

residual pressure before fully removing.

3. Remove the radiator hose clamp from the lower

left hand side radiator tank, draining the coolant

into the container.

4. Reinstall the hose and tighten the clamp.

5. Remove the upper and lower radiator hoses (1

and 3) from the coolant pump connections.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-22

6. Remove the vapour hose to coolant surge

tank connection at the radiator left hand tank.

7. Disconnect the vapour hose at the throttle

body (‘2’ in Figure 6B3-22 and reconnect to

the radiator tank.

8. Attach a lead-away hose at the radiator upper

hose outlet.

9. Attach a piece of hose between the flushing

gun and the radiator lower hose.

10. Connect and operate the flushing equipment

as recommended by the manufacturer.

NOTE: Apply air pressure gradually and not in

excess of 110 kPa. Otherwise radiator damage

will result.

11. Continue flushing until the water from the lead-

away hose runs clear.

12. Reinstall all disc onnected hoses, ensur ing that

spring hose clamps are positioned correctly

and/or tightened.

13. Fill the cooling system. Refer 2.3 DRAINING

AND FILLING COOLING SYSTEM, in this

Section.

14. Pressure test the cooling system to check for

leaks. Refer to 2.8 PRESSURE TESTING, in

this Section.

Figure 6B3-23

ENGINE:

1. With the coolant drained from the engine and

both radiator hoses disconnected, remove the

thermostat from the coolant pump housing.

Refer to 2.9 THERMOSTAT - Remove, in this

Section and dismantle from the thermostat

housing. Reinstall the thermostat housing

cover to the coolant pump.

2. Remove both heater hose connections from

the coolant pump, then seal both pump

openings, using a piece of sc rap hose and two

hose clamps.

3. Fit a lead-away hose to the thermostat

housing and a length of hose between the

coolant pump outlet fitting and the flushing

equipment.

4. Connect and operate the flushing equipment

as recommended by the manufacturer.

5. Continue flushing until the water fr om the lead-

away hose runs clear.

6. Reinstall all disc onnected hoses, ensur ing that

hose clamps are positioned correctly and/or

tightened.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-24

7. Fill the cooling system . Refer 2.3 DRAINING AND

FILLING COOLING SYSTEM, in this Section.

8. Pressure test the cooling system to check for

leaks. Refer to 2.8 PRESSURE TESTING, in this

Section.

HEATER HOSES AND CORE:

1. It is as sum ed that the f ollowing have already been

carried out:

a. The engine is at ambient temperature.

b. The screw-on pressure cap has been

removed.

c. The coolant has been drained.

2. Set the heater control to maximum.

3. Disconnect the heater hose from the rear

coolant pump fitting and the other from the T-

piece, leaving the T-piece and coolant surge

tank hose still connected.

4. Direct the hose disconnected from the T-

piece, into a suitable container and the other

hose to the flushing gun.

5. Connect and operate the flushing equipment

as recommended by the manufacturer.

6. Continue flushing until the water fr om the lead-

away hose runs clear.

7. Reinstall all disc onnected hoses, ensur ing that

hose clamps are positioned correctly and/or

tightened.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

8. Fill the cooling system. Refer 2.3 DRAINING

AND FILLING COOLING SYSTEM, in this

Section.

9. Pressure test the cooling system to check for

leaks. Refer to 2.8 PRESSURE TESTING, in

this Section.

Figure 6B3-25

COOLANT SURGE TANK AND HOSE:

1. It is as sum ed that the f ollowing have already been

carried out:

a. The engine is at ambient temperature.

b. The screw-on pressure cap has been

removed.

c. The coolant has been drained.

2. Remove the coolant surge tank hose from the T-

piece at the coolant pump and direct the open end

into a suitable container.

3. Connect the flushing equipment to the threaded

surge tank opening, then operate the equipment

as recommended by the manufacturer.

4. Continue flushing until the water from the lead-

away hose runs clear.

5. Reinstall all disconnected hoses, ensuring that

spring hose clamps are positioned correctly

and/or tightened.

CAUTION: ALWAYS WEAR PROTECTIVE SAFETY

GLASSES WHEN WORKING WITH SPRING TYPE

HOSE CLAMPS. FAILURE TO DO SO COULD

RESULT IN EYE INJURY.

6. Fill the cooling system . Refer 2.3 DRAINING AND

FILLING COOLING SYSTEM, in this Section.

7. Pressure test cooling system, refer to

2.8 PRESSURE TESTING in this Section and

check for external coolant leaks.

2.6 ENGINE ACCESSORY DRIVE BELT TENSION

Drive belt tension is provided by a tensioner

assembly (1). The tensioner is an idler pulley

mounted on a s pring-loaded arm that maintains the

drive belt (2) at the correct tension, without

imposing undue loads on the various components.

Figure 6B3-26

Drive belt tens ion is within the precribed lim its if the

indicator (ar row) on the tensioner is between points

‘A’ and ‘B’ on the tensioner bracket .

If replacement is indicated, refer to 2.7 ENGINE

ACCESSORY DRIVE BELT, in this Section.

Figure 6B3-27

2.7 ENGINE ACCESSORY DRIVE BELT

REMOVE

1. Remove the engine dress cover (1) after

removing the four decorative retaining nuts

(2).

Figure 6B3-28

2. Us ing a 15 mm ring spanner , rotate the engine

accessory drive belt tensioner (1) in the

direction indicated, to reduce belt tension.

3. While holding the tensioner in the reduced

tension position, remove the accessory drive

belt from the engine, taking note of the belt

routing.

Figure 6B3-29

INSPECT

The four views in Figure 6B3-30 show the various stages of drive belt wear, to assist in belt replacement decisions.

NOTE: Condition of the belt ribs can be better assessed if the belt is wrapped over the coolant pump drive pulley.

Legend:

A New Belt: No cracks or chunks.

B Moderately Used Belt: Few cracks, with some wear on the ribs and in the grooves. Belt replacement not required.

C Severely Used Belt: Several cracks per 30 mm. Should be replaced before chunking occurs

D Failed Belt: Separation of rib material from backing (chunking). Belt must be replaced immediately.

Figure 6B3-30

REINSTALL

1. While having an assistant hold the tensioner in

the unloaded position (arr ow) with a 15 m m ring

spanner, install the engine accessory drive belt,

routing in the same manner as noted on

removal and as shown in Figure 6B3-31.

Figure 6B3-31

2.8 PRESSURE TESTING

SCREW-ON PRESSURE CAP TESTING

1. Allow engine to cool to ambient temperature

(less than 50°C), then remove radiator cap.

CAUTION: DO NOT REMOVE SCREW-ON

PRESSURE CAP WHILE THE ENGINE

COOLANT TEMPERATURE IS ABOVE 50°

°°

°C, AS

PERSONAL INJURY WILL MOST LIKELY

OCCUR.

2. Thoroughly clean the threads and internal cap

parts, using clean cloth and water.

3. Install the the Screw-on Cap Test Adapter J

24460-92 onto a commercially available cooling

system pressure tester (2).

4. Install the pressure cap (1) onto the male

threaded half of the Test Adapter J 24460-92,

then slowly pressurise the cap using the

pressure tester hand pump, noting the point at

which the cap unloads.

The cap is serviceable if it unloads slightly

above the pressur e range of 100 kPa and holds

pressure. Should the cap fail to reach or hold

the specified pressure, install a new pressure

cap.

5. Prior to installing screw-on pressure cap, check

that the coolant surge tank filler neck threads

and cap seating surface are clean and

undamaged.

Figure 6B3-32

COOLING SYSTEM PRESSURE TESTING

1. Allow engine to cool to ambient temperature

(less than 50°C), then check that the coolant

level is correct.

CAUTION: DO NOT REM O VE SURGE TANK

CAP WHILE THE ENGINE COOLANT

TEMPERATURE IS ABOVE 50°

°°

°C, AS

PERSONAL INJURY MAY RESULT.

2. Carefully remove the screw-on pressure cap.

3. Connect the female half of Test Adapter J

24460-92 to a commercially available cooling

system pressure tester, then install the

assembly to the coolant surge tank filler neck.

Dry any residual coolant around radiator filler

neck with compressed air. Pressurise cooling

system to no more than 110 kPa and check

for leaks at the following points:

a. All hoses and hose connections.

b. Radiator seams and core.

c. Corroded or faulty engine core plugs.

d. Coolant pump and gaskets and O-ring

seals.

e. Vehicle heater system.

f. Check engine oil dipstick for evidence of

engine oil contamination with coolant.

4. If pressure will not hold, there is a leak in the

cooling system. Repair as required.

NOTE: If visible loss of coolant is not evident

from pressure testing, then the use of a dye

and black light, may be necessary. Refer to

3.4 BLACK LIGHT AND DYE LEAK DIAGNOSIS

METHOD, in this Section.

Figure 6B3-33

2.9 THERMOSTAT

REMOVE

1. Allow engine to cool to ambient temperature

(less than 50°C), then slowly remove the

screw-on pressure cap from the coolant surge

tank.

CAUTION: DO NOT REMOVE SURGE TANK

CAP WHILE THE ENGINE COOLANT

TEMPERATURE IS ABOVE 50°

°°

°C, AS PERSONAL

INJURY MAY RESULT.

2. Drain the engine coolant into a suitable

container. Refer to 2.3 DRAINING AND

FILLING COOLING SYSTEM, in this Section.

3. Disconnect radiator hose from coolant inlet at

the thermostat housing.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-34

4. Remove thermostat housing bolts (1), then

remove the cover (2), thermostat and O-ring

seal from the coolant pump.

Figure 6B3-35

TEST

1. Suspend thermostat and a suitable thermometer

in a container of 50/50 DEX-COOL® and water.

NOTE: Neither the therm ostat nor ther mom eter should

rest on the bottom of the container bec ause of uneven

concentration of heat at this point when the container is

heated.

2. Heat c ontainer until therm os tat begins to open.

Agitate solution to ensure uniform temperature.

Note temperature and ensure thermostat

opens within specified temperature range.

3. Continue heating the solution until the

thermostat is fully open. Again agitate the

solution and take note of the temperature

4. Ins tall a new therm ostat if it does not meet the

specified temperatures.

Thermostat Specifications

Opening Temperature 86° C

Fully Open Temperature 100° C

Figure 6B3-36

DISMANTLE

Important: Only dismantle the thermostat if a

revese flushing operation of the cylinder block is to

be carried out. If testing shows that replacement is

required, the thermostat and housing are only

serviced as a complete assembly.

1. Sec ur e the thermos tat housing by gripping in a

vice fitted with soft jaws.

2. While compres sing the springs with one hand,

rotate the retaining bar from the housing lugs

and release.

CAUTION: Wear safety glasses to avoid

potential eye injury.

Figure 6B3-37

3. Carefull lay all parts out in order, for ease of

reassembly.

Legend:

1. Bypass Valve.

2. Bypass Valve Spring.

3. Thermostat Closing Spring.

4. Wax Pellet and Valve Assembly.

5. Thermostat Housing.

REASSEMBLE

Reassembly is the reverse of disassembly

procedures, except that the valve seat in the

thermostat housing m ust be checked for corrosion,

scratching or other damage and the valve seating

surface wiped with a clean rag.

Figure 6B3-38

REINSTALL

1. Shak e the therm ostat assem bly to ensure that

the air bleed check ball (1) in the housing is

free and not jammed.

2. Thoroughly clean the coolant pump to

thermostat housing sealing surfaces, taking

care not to scratch any machined alloy

surfaces.

3. Ins tall thermos tat assembly, with a new O-r ing

(2), fitted to the coolant pump housing (3).

4. Install thermostat housing to coolant pump

housing attaching bolts and tighten to the

correct torque specification.

THERMOSTAT HOUSING TO

COOLANT PUMP BOLT 13 - 15 Nm

TORQUE SPECIFICATION

5. Install radiator hose and clamp to thermostat

housing.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

6. Refill cooling system, refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM in this

Section.

7. Check for cooling system leaks, refer to

2.8 PRESSURE TESTING in this Section.

Figure 6B3-39

2.10 COOLANT RECOVERY SURGE TANK

REMOVE

1. Allow engine to cool to ambient temperature

(less than 50° C), then slowly remove the

screw-on pressure cap from the coolant surge

tank.

CAUTION: DO NOT REMOVE SURGE TANK

CAP WHILE THE ENGINE COOLANT

TEMPERATURE IS ABOVE 50°

°°

° C, AS

PERSONAL INJURY MAY RESULT.

2. Drain the engine coolant into a suitable

container. Refer to 2.3 DRAINING AND

FILLING THE COOLING SYSTEM, in this

Section.

3. Dis connect radiator hose f rom s urge tank inlet

fitting (1), vapour hose (2) and overflow

hose (3).

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-40

4. Grasp the surge tank (1) firmly with both

hands, pivot as shown (arrow ‘A’) to dislodge

the surge tank (1) from the rear anchor point,

then pull inboard (arr ow ‘B’) toward the engine

to remove from the anchor point attached to

the inner fender skirt.

Figure 6B3-41

INSPECT

1. Drain contents from surge tank assembly.

2. Clean surge tank assembly with water and dry,

using compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

3. Check surge tank and assembly for damage, e.g.

abrasions, c r acks or dis tor tion. Install a new sur ge

tank assembly as required.

REINSTALL

Reinstallation of the surge tank assembly is the

reverse of removal procedures, noting the following

points:

1. Refill c ooling system , ref er to 2.3 DRAINING AND

FILLING COOLING SYSTEM in this Section.

2. Check for cooling system leaks, refer to

2.8 PRESSURE TESTING in this Section.

2.11 ENGINE COOLANT LEVEL SWITCH

REMOVE

1. With the coolant hoses still connected, grasp

the recovery surge tank (1) firmly with both

hands.

2. Pivot as shown (arrow ‘A’) to dislodge the

recovery surge tank (1) from the rear anchor

point, then pull inboard (arrow ‘B’) toward the

engine to remove from the anchor point

attached to the inner fender skirt.

Figure 6B3-42

5. Position the recovery surge tank (1) to gain

access to the engine coolant level switch.

6. Disconnect the coolant level switch harness

connector.

Figure 6B3-43

7. Using commercially available long nose pliers,

place the opened nose of pliers each side of

the coolant switch (1) between the recovery

surge tank (2) and the coolant level switch as

shown.

8. Using the r ecovery surge tank (2) as a place of

purchase, dislodge the coolant switch (1) from

the recovery surge tank by wiggling the switch

gently side to side while moving in an upward

direction away from the tank. The switch is a

very tight fit and will require a little force to

dislodge it from the recovery surge tank.

Figure 6B3-44

INSPECT

1. Clean the coolant level switch and tank

aperture area if required using compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Check the free movement of the coolant level

float located in the recovery surge tank.

3. Check the recovery surge tank assembly for

damage, e.g. abrasions, cracks or distortion.

Install a new surge tank assembly as required,

refer to Section 2.10 COOLANT RECOVERY

SURGE TANK.

4. Chec k the operation of the coolant level s witch.

For coolant level switch diagnostics refer to

Section 6C3-2C FUNCTION CHECKS - GEN

III V8 - ENGINE COOLANT LEVEL SWITCH

DIAGNOSIS.

Figure 6B3-45

REINSTALL

1. Apply a sm all amount of lubricant to the seal of

the coolant level switch prior to installation.

Figure 6B3-46

2. Using suitable hand protection, install the

coolant level switch (1) by pushing it firmly into

the recovery surge tank (2) aperture.

3. Check the coolant level switch is completely

home in the surge tank aperture by trying to

remove it by hand only.

Figure 6B3-47

4. Connect the coolant level switch harness

connector to the recovery surge tank and

cool ant level switch assembly (1).

Figure 6B3-48

5. Re-install the recovery surge tank and coolant

level switch assembly (1) by pushing the tank

on to the anchor point attached to the inner

fender skirt (2), then push the tank on to the

rear anchor point (3) and bottom anchor point

(4).

6. Check the tank securely mounted to both

anchor points.

Figure 6B3-49

2.12 OIL P AN UNDER-TRAY

REMOVE

1. Raise front of vehicle and place on safety

stands. Refer to Section 0A GENERAL

INFORMATION of the VT Series I Service

Information for location of jacking points.

2. Rem ove the four bolts securing the under-tray

to the crossmember and remove tray from

vehicle.

REINSTALL

1. While holding the under-tray (1) up to the

crossmember with one hand, install all four

securing bolts (2).

2. Tighten all four bolts (2) to the correct torque

specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 - 35 Nm

Figure 6B3-50

2.13 AIR BAFFLES

REMOVE

1. Raise front of vehicle and place on safety

stands. Refer to Section 0A GENERAL

INFORMATION of the VT Series I Service

Information for location of jacking points.

2. Remove the oil pan under-tray. Refer

2.12 OIL PAN UNDER-TRAY, in this Section.

3. Rem ove the lower rear air chute baffle sc rews

(two places), lower the rear of the rear air

chute baffle (3), slide the baffle rearward to

disengage from the front baffle, then remove

from the vehicle.

4. Rem ove lower front baf fle (1) to cros smem ber

fasteners (2) (four places) and remove front

air chute baffle (1) from the vehicle.

REINSTALL

1. Reinstallation is the reverse to removal

procedures.

NOTE: Do not overtighten any of the fasteners.

Figure 6B3-51

2.14 COOLANT PUMP

REMOVE

NOTE: Apart from the rear cover, O-ring and

thermostat assembly, the coolant pump is not

serviceable and if found to be faulty must be

replaced as an assembly.

1. Allow engine to cool to ambient temperature

(less than 50°C), then s lowly remove sc rew-on

pressure cap from the coolant surge tank.

CAUTION: DO NOT REMOVE SCREW-ON

PRESSURE CAP WHILE THE ENGINE

COOLANT TEMPERATURE IS ABOVE 50°

°°

°C, AS

PERSONAL INJURY MAY RESULT.

2. Disconnect battery earth lead.

3. Remove engine dress cover decorative nuts

(2), then remove the cover (1).

4. Loosen the two intake hose clamps, then

remove the hose (3).

5. Loosen coolant pump drive pulley bolts.

Figure 6B3-52

6. Remo ve engine accessor y drive belt (2), using

a 15 mm ring spanner, refer to 2.7 ENGINE

ACCESSORY DRIVE BELT, in this Section.

Figure 6B3-53

7. Drain engine coolant. Refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM, in this

Section.

8. Disconnect both heater hoses, the outlet and

inlet hoses from the coolant pump.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-54

9. Remove the loosened four bolts securing the

coolant pump pulley to the hub. Remove

pulley .

Figure 6B3-55

10. Remove the two bolts (1) securing the drive

belt tensioner (2) to the coolant pump housing

and set the tensioner to one side.

Figure 6B3-56

11. Loosen, then r em ove the six bolts ( 1) sec uring

the coolant pump (2) to the cylinder block.

12. If necessary, use a soft faced hammer to

lightly tap coolant pump housing (2) to

dislodge it from the cylinder block.

13. Remove coolant pump gaskets (3) and

discard.

Figure 6B3-57

DISMANTLE

NOTE: Apart from the ser vice operations des c ribed

here, there are no other serviceable parts in the

coolant pump assembly and if required, then the

assembly must be replaced as a complete unit.

1. If required, remove the five bolts (4) securing

the rear cover (3) to the coolant pum p (2). Tap

with a soft faced hammer to dislodge the cover

from the pump body.

2. Remove the sealing O-ring (1) from the

coolant pump body (2).

3. For thermostat remove, test and reinstall

procedures , refer to 2.9 THERMO STAT in this

Section.

Figure 6B3-58

CLEAN AND INSPECT

1. Remove the old gasket or gasket material from

the coolant pump sealing surfaces and cylinder

block, taking care not to scratch the machined

surfaces.

2. Clean all dirt and debris from the coolant pump

housing.

3. Inspect the coolant pump for the following:

• Gasket surfaces for excessive scratches or

gouging.

• Hose sealing sur faces f or scr atches, gouging

or corrosion.

• Restrictions, corrosion or evidence of

cavitation within the internal coolant

passages or on the pump impeller.

• Excessive side-to-side play in the pulley

shaft.

• A loose belt pulley or a pulley with excessive

wear or scoring on the belt tracking area.

• Evidence of coolant leakage at the coolant

outlet housing or rear cover gasket (if these

parts have not been removed).

• Leakage at the coolant pump vent hole. A

stain around the vent hole is acceptable. If

leakage occurs (dripping) with the engine

running and the cooling system pressurised,

replace the coolant pump.

REASSEMBLE

1. Install a new O-ring seal to the cleaned groove in

the pump housing, then install the cover and

retaining bolts.

2. Gradually tighten every second bolt until the

correct torque specification is reached.

COOLANT PUMP REAR COVER

BOLT TORQUE SPECIFICATION 13 - 15 Nm

REINSTALL

Reinstallation is the reverse to removal ecept for the

following items:

1. Ensure that the coolant pump and cylinder block

surfaces are clean and dry.

2. Using two bolts on each side as guides, install

NEW gaskets over them and install the coolant

pump to the cylinder block.

3. Install remaining bolts and tighten to the correct

torque specification, in two stages.

COOLANT PUMP BOLT Stage 1: 15 Nm

TORQUE SPECIFICATION Stage 2: 25 Nm

4. Install the coolant pump pulley and attaching

bolts, tightening to the correct torque specification.

COOLANT PUMP PULLEY BOLT Stage 1: 10 Nm

TORQUE SPECIFICATION Stage 2: 25 Nm

5. Install the engine accessory drive belt tensioner

and attaching bolts, tightening to the correct

torque specification.

ENGINE ACCESSORY DRIVE BELT

TENSIONER BOLT 40 - 60 Nm

TORQUE SPECIFICATION

6. Install all removed radiator hoses and clamps.

CAUTION: ALWAYS WEAR PROTECTIVE SAFETY

GLASSES WHEN WORKING WITH SPRING TYPE

HOSE CLAMPS. FAILURE TO DO SO COULD

RESULT IN EYE INJURY.

7. Install the engine accessory drive belt. Refer

2.7 ENGINE ACCESSORY DRIVE BELT, in this

Section.

8. Refill c ooling system , ref er to 2.3 DRAINING AND

FILLING COOLING SYSTEM in this Section.

9. Check for cooling system leaks, refer to

2.8 PRESSURE TESTING in this Section.

2.15 COOLING FAN AND SHROUD ASSEMBLY

REMOVE

1. Allow engine to cool to ambient temperature

(less than 50°C), then s lowly remove sc rew-on

pressure cap from the coolant surge tank.

CAUTION: DO NOT REMOVE SCREW-ON

PRESSURE CAP WHILE THE ENGINE

COOLANT TEMPERATURE IS ABOVE 50°

°°

°C, AS

PERSONAL INJURY MAY RESULT.

2. Disconnect battery earth lead.

3. Remove engine dress cover decorative nuts

(2), then remove the cover (1).

4. Loosen the two intake hose clamps, then

remove the hose (3).

5. Drain engine coolant. Refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM, in this

Section.

Figure 6B3-59

6. Press the retaining tangs on main wiring

harness to cooling fan motor wiring harness

connectors (1 and 2) and separate

connectors.

Figure 6B3-60

7. Remove cooling fan and shroud to radiator

attaching bolts (1), remove fan and shroud

assembly (2) from engine compartment.

Figure 6B3-61

Techline

DISASSEMBLE

1. Holding f an blade assem bly (1), r emove f an to

motor shaft attaching nut (2) and remove fan.

2. If the f an blade assem bly is a tight fit on motor

shaft, proceed as follows;

a. Reinstall attaching nut (1) and leave

loose.

b. Holding fan blade assembly up, tap on

end of motor shaft with a soft faced

hammer. Remove attaching nut and fan

blade assembly.

3. Remove motor assembly wiring harness (3)

from the shroud clip and attaching straps (4).

4. Remove screws (5) attaching the motor

assembly (6) to the shroud (7), then remove

the motor.

Figure 6B3-62

REASSEMBLE

Reassembly is the reverse of disassembly

procedures, noting the following points:

1. Tighten motor to shroud attaching screws to the

correct torque specification. Do not over-tighten.

FAN MOTOR TO SHROUD SCREW

TORQUE SPECIFCATION 2.7 - 5.0 Nm

2. Install the fan blade assembly to motor shaft,

apply thread locking agent such as Loctite 242 or

equivalent to the motor shaft thread, install the

attaching nut and tighten to the correct torque

specification.

FAN TO MOTOR S HAFT ATTACHING

NUT TORQUE SPECIFICATION 5.0 - 7.5 Nm

3. Install new tie straps to secure the motor wiring

harness to the radiator shroud.

REINSTALL

Reinstallation of the cooling fan and shroud assembly

is the reverse of removal procedures, noting the

following points:

1. Ensure that fan and shroud assembly to radiator

attaching bolts are tightened to the correct torque

specification.

COOLING FAN AND SHROUD TO

RADIATOR ATTACHING BOLT 3 - 4.5 Nm

TORQUE SPECIFICATION

2. Check cooling fan operation, refer to

Section 6C3 POWERTRAIN MANAGEMENT -

GEN III V8 ENGINE of the VT Series II Service

Information. Check rotation direction of cooling

fan.

2.16 RADIATOR

REMOVE

1. Allow engine to cool to am bient temperature (less

than 50°C), slowly loosen screw-on pressure cap

at the coolant surge tank to relieve any residual

coolant pressure, then remove.

CAUTION: DO NOT REMOVE SURGE TANK CAP

WHILE THE ENGINE COOLANT TEMPERATURE IS

ABOVE 50°

°°

°C, AS PERSONAL INJURY MAY

RESULT.

2. Disconnect battery earth lead.

3. Remove engine dress cover decorative nuts

(2), then remove the cover (1).

4. Loosen the two intake hose clamps, then

remove the hose (3).

Figure 6B3-63

5. Loosen radiator lower hose worm drive clamp

from radiator connection (1), remove the hose

and allow coolant to drain into a suitable

splash tray.

6. Rem ove radiator upper hos e from r adiator (2),

after releasing the spring type hose clamp,

using suitable pliers.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6B3-64

Techline

7. Remove the 4 radiator upper shroud retainers

(2), release the vapour hose clip from the

radiator f an shr oud, then remove shroud (1) by

lifting on the driver’s side first to release the

locating tab on the left hand side.

Figure 6B3-65

8. If vehicle is equipped with an automatic

transmission, disconnect the transmission oil

cooler line quick connect fittings, using Tool

No. AU525.

Plug hoses and oil cooler unions to prevent

foreign matter entry.

Important: If the quick connect release tool is not

available and the coolant line, flar e nut connections

are rem oved at the lef t hand radiator tank , then it is

vital that a 25 mm back-up spanner is used on the

radiator tank fitting before loosening the pipe flare

nut.

If the f itting is loosened by mistak e, then it must be

replaced with a new part, as micro-encapsulated

sealant is used on the fitting threads that require

the part to be replaced.

Refer to RADIATOR REPAIR PROCEDURE, next

in this Section.

Figure 6B3-66

9. Disconnect the wiring harness to cooling fan

motor wiring harness connectors (1 and 2) by

pressing on the locking tangs. Separate the

connections.

Figure 6B3-67

10. Using a screwdriver, compress and lever out

radiator retaining clip (1) from radiator upper

mounting bracket, on each side.

11. Lift radiator upwards out of lower insulators

and remove radiator assembly from vehicle.

Remove upper insulators (2) from radiator

upper mounting pins.

Figure 6B3-68

REINSTALL

Reinstallation of the radiator is the reverse of removal

procedures, noting the following points:

1. Before installing radiator, inspect core to ensure

that there is no foreign matter such as insects in

the core fins. Clean out between core fins with

com press ed air, work ing f rom the engine side and

blowing forwards.

2. Ensure that radiator lower mounting pins are

correctly located in lower insulators.

3. Ensure that upper insulators (2) are installed

on each of the upper mounting pins and

radiator retainers (1) are correctly installed on

each side of the radiator by chacking that the

clips engage on both sides of the channel

support bracket.

4. If removed, tighten cooling fan and shroud

assembly to radiator attaching bolts to the

correct torque specification.

COOLING FAN AND SHROUD TO

RADIATOR ATTACHING BOLT 3.0 - 4.5 Nm

TORQUE SPECIFICATION

Figure 6B3-69

5. If the vehicle is fitted with an automatic

transm ission, install both quic k connec t fittings

to the radiator cooler pipes, then tug on each

to ensure correct installation.

Figure 6B3-70

6. Reinstall the upper radiator shround (1),

reinstall the vapour hose clip to the radiator

fan shroud and secure with the four fasteners

(2).

NOTE: Do not over-tighten fasteners.

7. Refill cooling system, refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM in this

Section.

8. Check for coolant leaks, refer to

2.8 PRESSURE TESTING in this Section.

9. Check cooling fan operation, refer to

Section 6C3 POWERTRAIN MANAGEMENT

- GEN III V8 ENGINE of the VT Series II

Service Information.

Figure 6B3-71

RADIATOR REPAIR PROCEDURE

REPAIRABLE LEAKS

There are two types of leaks that can be repaired

on the aluminium-plastic radiator; core leaks and

automatic transm ission oil cooler seal leak s. Leaks

in the plastic tanks or the seals between the side

tanks and the headers cannot be repaired,

therefore the radiator must be replaced.

Core leaks may occur in a tube or in the joints

between the tubes and the headers. Seal leaks

may occur in the joints between the plastic tanks

and the headers or in the joints between the oil

cooler f ittings and the tank (vehicles with autom atic

transmission).

While some leaks may be repaired while the

radiator is installed in the vehicle, it is strongly

recommended that the radiator is first removed

from the vehicle.

Legend:

1. Side Tank Seal

2. Core Tubes

3. Side Tank Seal

4. Oil Cooler Pipe Fittings

5. Joint Between Tube and Header

NOTE: Minor damage to tubes, or tube to header

joint (holes up to 1 mm diameter max.) can be

repaired. Core r eplacem ent is nec essar y if damage

is any greater.

Figure 6B3-72

REPAIR METHOD

Repairs to the aluminium radiator core should only

be made using the recommended 'Aluminised

Silicon' based liquid repair agent, in accordance

with the recommended procedure outlined in

GENERAL CORE REPAIR, later in this Section.

Refer to Holden Parts Information for Aluminised

Silicon base liquid part number.

For damaged areas that are between the cooling

fins, it may be necessary to remove some of the

fins. Do not remove more fins than is necessary.

Usually 6 mm (distance ‘A’) beyond the leak or

damage area, up to a maximum of 25 mm of total

fin material, is enough to make an effective repair.

Figure 6B3-73

TUBE BLOCKING

If a tube is severely damaged, it can be blocked off.

NOTE: Do not block off more than two tubes in a

radiator. Blocking off more than two tubes will

reduce the cooling capacity of the system and

possibly result in an overheated engine.

The tube s hould be cut off six mm from the header

(1) and pinched shut before it is cleaned and

sealed, ref er to GENERAL CORE REPAIR, later in

this Section.

Figure 6B3-74

HEADER REPAIR

If the header or a tube near the header requires a repair, the side tank does not have to be removed.

GENERAL CORE REPAIR

The need for careful preparation of the surface in the repair area cannot be over-emphasised. If the leak area surface is

not clean, the repair material will not adhere to the surface.

1. Remove and drain the cooling system. Refer to 2.3 DRAINING AND FILLING COOLING SYSTEM in this Section.

2. If necessary, carefully cut away fins to expose the damaged area.

NOTE: Do not cut away more than 25 mm total of fin material.

3. Clean away dirt etc. with water. Dry the affected area using hot air from a hair drier.

NOTE: Do not apply flame to dry damaged area.

4. Clean affected area with petrol to remove any traces of oil.

5. Thoroughly stir contents of repair agent.

In cas es of extended shelf life, the silic on in solution m ay separate f rom the thinner carrier . Should this occur, m ix

contents well until agent is homogeneous again.

6. Apply repair agent sparingly to dam aged area. Do not apply an excessive am ount, as this will cause a bloc k age of

the radiator tube.

Use a clean, dry wooden applicator to 'drip' the repair agent onto damaged area of radiator.

7. Allow radiator to stand in a clean, dry area for a minimum of three hours (at ambient temperature of 20 - 30° C)

with adequate ventilation.

NOTE: Do not apply heat or flame to promote drying.

8. Install radiator, refer to 2.16 RADIATOR, Reinstall in this Section.

TRANSMISSION OIL COOLER LEAK TEST

If the transmission oil cooler is suspected of leaking transmission fluid, test it before removal as follows:

1. Disconnect oil cooler pipes from radiator connections, after holding the pipe fitting with a 25 mm back-up spanner.

Important: Always use a back-up spanner to hold the flare nut fitting screwed to the radiator header tank, before

loosening the cooler pipe connection.

2. Usuing suitable screwed connections, plug one of the connections and connect an air supply to the other

connection.

3. Lay the radiator flat on a bench top and fill with clean water until both hose fittings are full and visible.

4. Apply air pressure GRADUALLY, increasing it up to a maximum of 103 kPa.

If bubbles appear in the water visible in the radiator hose fittings, then the radiator assembly must be replaced.

TRANSMISSION OIL COOLER SEAL REPLACEMENT.

The oil cooler pipe fitting can be replaced without removing the side tank.

1. Remove radiator, refer to 2.16 RADIATOR, - REMOVE in this Section, and lay radiator on a flat surface.

2. Using a 25 mm socket and bar, carefully remove the cooler pipe fitting from the side tank.

3. Blow dry all surfaces on side tank and oil cooler.

4. Install a NEW flare nut fitting, without any

added lubricant or sealant. Take particular

care that the sealing O-rings are not displaced,

cut or damaged in any way, during the

installation and tightening process.

5. Tighten flare nut fitting to oil cooler, to the

correct torque specification.

OIL COOLER TO SIDE TANK NUT

TORQUE SPECIFICATION 20 Nm

6. Conduct a pressure check of the oil coolers.

See T r ansmiss ion O il Cooler Leak T es t, in this

Scetion.

7. Reinstall radiator, refer to 2.16 RADIATOR,

REINSTALL in this Section.

8. Fill the cooling system with the

recommmended coolant, refer to

2.3 DRAINING AND FILLING COOLING

SYSTEM, in this Section.

9. Check the cooling system for leaks, refer to

2.8 PRESSURE TESTING in this Section.

Figure 6B3-75

3. ENGINE COOLING SYSTEM DIAGNOSIS

3.1 ENGINE OVERHEATING

DEFINITION: Engine temperature lamp comes ON and stays ON, or the temperature gauge shows hot, or coolant

overflows from the surge tank onto the ground while the engine is running.

Step Action Value Yes No

1 1. Check for a loss of cool ant.

2. Ref er 2.2 COOLANT MAINTENANCE, Topping Up Cooling

System, in this Section.

Is there a l oss of coolant?

—

Refer 3.2 LOSS

OF COOLANT,

in this Section.

Go to Step 2

2 1. Check for weak engine coolant soluti on.

2. Ref er 2. 2 COOLANT MAINTENANCE, Testing Cool ant

Concentrat i on, i n this Section.

Does the engine still overheat?

—

Go to Step 3

System OK

3 Check for obst ructed radiator ai r flow or bent radiator fins.

2. I f necessary, rem ove or rel ocate added-on parts that block air

to the radiator. Clean away any insects, l eaves, or other

debris.

Does the engine still overheat?

—

Go to Step 4

System OK

4 1. Check for a loss of sys tem pres sure.

2. Conduc t a test on the pressure cap. Refer 2. 8 P RESSURE

TESTING, Screw-On Pressure Cap Testing, in thi s Section.

Does the engine still overheat?

—

Go to Step 5

System OK

5 1. Check for a faulty Engine Coolant Temperature (ECT) sensor.

Refer 6C3 POWERTRAI N MANAGEMENT - GEN III V 8

ENGINE, of the VT S e ri es II Servi ce Information.

2. Replace sensor as necessary.

Does the engine still overheat?

—

Go to Step 6

System OK

6 1. Check for a dam aged coolant surge tank.

2. Chec k for a leak i ng or kinked surge tank hose.

3. I f necess a ry, repl ace the surge t ank hose and/or repl ace the

coolant s urge tank. Ref er 2. 10 COOLANT SURGE TANK, in

this Section.

Does the engine still overheat?

—

Go to Step 7

System OK

7 1. Check the tens i on of the engine accessory dri ve belt.

Refer to 2.6 ENGINE ACCESSORY DRIVE BELT TENSION,

in this Section.

2. Replace the engine ac cessory dri ve belt as necessary. Ref er

to 2.7 ENGINE ACCESSORY DRIVE BELT, in this Section.

Does the engine still overheat?

—

Go to Step 8

System OK

8 1. Check for blocked cooling system passages.

2. Revers e flush the cooling system . Refer to 2.5 CLE A NING

THE COOLING SYSTEM, in this Section.

Does the engine still overheat?

—

Go to Step 9

System OK

9 1. Check for inco rrect or dam aged cooling fan blade(s).

2. Chec k for the correct f an bl ade(s) part num ber.

3. Replace fan/s as necessary. Refer 2.14 COOLING FANS AND

SHROUD ASSEMBLY, in this Section.

Does the engine still overheat?

—

Go to Step 10

System OK

10 1. Check for correct operation of cooling fans. Refer 6C3

POWERT RAIN MANAGEME NT - GE N III V 8 E NGINE,

of the VT Series II Service Inform ation.

2. Replace cooling fan/s and/ or motor, as necessary. Refer 2. 14

COOLING FANS AND SHROUD ASSEMBLY, in this Section.

Does the engine still overheat?

—

Go to Step 11

System OK

11 1. Check for correct thermostat operation. Ref e r 2. 9

THERMOSTAT, Test, in this Section.

2. Replace thermostat assem bl y as necessary. Refer 2.9

THERMOSTAT, in this Section.

Does the engine still overheat?

—

Go to Step 12

System OK

12 1. Check for correc t coolant pump operation.

2. Replace coolant pump ass embly as necessary. Refer 2.13

COOLANT PUMP, in this Section.

Does the engine still overheat?

—

Go to Step 13

System OK

13 1. Check the radiator cooling capacity.

Is the radi ator the correc t part for t he GE N III V 8 engi ne? —

System OK

Go to Step 14

14 1. Replace the radiator with t he correct part .

Is t he repai r complete? —

System OK —

3.2 LOSS OF COOLANT

DEFINITION: The coolant level in the surge tank continually requires topping up or there is evidence of a sudden

coolant loss from the surge tank.

Step Action Value Yes No

1 1. Check for an inco rrect or fault y screw-on pressure cap.

Conduct a t est on the pres sure cap. Ref er 2.8 PRESS URE

TESTING, Screw-On Pressure Cap Testing, in thi s Section.

2. Replace the screw-on pressure cap as necessary.

Is a coolant loss still evident ?

—

Go to Step 2

System OK

2 1. Check for a leaki ng or damaged cool ant surge tank.

2. Replace the coolant surge tank . Refer 2.10 COOLANT

SURGE TANK, in this Section.

Is a coolant loss still evident ?

—

Go to Step 3

System OK

3. 1. Conduc t a pressure test of t he cooling sys tem. Refer Refer 2.8

PRESSURE TESTING, Cooling Syst em Pres s ure Testing, i n

this Section.

Does tes t indicat e a pressure loss in the c ool i ng system?

—

Go to Step 4

System OK

4. Is there evi dence of an external coolant l eak? — Go to Step 5 Go to Step 12

5. 1. Chec k for loos e or damaged surge t ank, radiator and heat er

hoses. Ref er 2.4 COOLANT HOSES , i n this Sec tion.

2. Replace hose/s as necessary.

Is a coolant loss still evident ?

—

Go to Step 6

System OK

6. 1. Chec k for a cool ant l eak from the coolant pump gaskets.

2. Replace gasket s as necessary. Ref er 2. 13 COOLANT PUMP,

in this Section.

Is a coolant loss still evident ?

—

Go to Step 7

System OK

7. 1. Chec k for a cool ant l eak from the coolant pump, rear O-ring

seal and thermost at housing O-ring seal .

2. Replace O-ring seals as necessary. Ref er 2.9 THERMOSTAT

and 2.13 COOLANT PUMP, i n t hi s Secti on.

Is a coolant loss still evident ?

—

Go to Step 8

System OK

8. 1. Chec k for a cool ant l eak from the coolant pump, s haft seal.

2. Replace coolant pump as necessary. Refer 2.13 COOLANT

PUMP, in this Section.

Is a coolant loss still evident ?

—

Go to Step 9

System OK

9. Inspec t the radiator f or coolant leak s.

Are coolant l eaks from the radiat or evi dent? —

Go to Step 10

System OK

10. 1. If radiator leak s are mi nor, repai r as detailed i n 2. 15

RADIAT OR, Radiator Repair P rocedure, in thi s Sect i on.

2. I f radiator cool ant leaks are major, repl ace the radiator. Refer

2.15 RADIATOR, in t hi s Sect i on.

Is a coolant loss still evident ?

—

Go to Step 11

System OK

11. 1. Check f or coolant leak s from the heater core.

2. Replace heater core as necessary. Refer 2B A IR

CONDITIONING - RE MOVA L & INSTALLATION, of the VT

Series I Service Inform ation.

Is a coolant loss still evident ?

—

Go to Step 12

System OK

12. 1. Chec k for cool ant l eaks from the fol l owing;

• Engine bl ock plugs .

• Vapour pipe and/or fittings

• Cylinder head gasket/ s.

2. Make the necess a ry reapi rs or replace affected c omponents .

Refer ENGINE MECHANICAL - GEN III V8 ENGINE,

of the VT Seri es II S ervi ce Information.

Is/ are t he repai r/s complete?

—

System OK

—

3.3 ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE

Step Action Value Yes No

1 1. Check for correct coolant level i n t he coolant s urge tank.

When checked col d, the level s houl d be at the FULL COLD

mark.

Is t he coolant level correct?

—

Go to Step 3

Go to Step 2

2 1. Top up with correct mixture of DEX-COOL® coolant additive

and clean, good quality water. Ref er 2.2 COOLANT

MAINTENANCE, in this Section.

Does the engine reach normal operating temperature now?

—

System OK

Go to Step 3

3 1. Check for a blockage i n the cooling s ystem passages.

2. Reverse f l ush the cooli ng system. Refer 2. 5 CLEANING

COOLING SYSTEM, in this Section.

Does the engine reach normal operating temperature now?

—

System OK

Go to Step

4 1. Check that the c orrect thermostat is fi tted.

2. Check that the thermost at is not stuck in the open posi tion.

3. Replace the therm ostat as necessary. Refer 2.9

THERMOSTAT, in this Section.

Are repairs complete?

—

System OK

—

3.4 BLACK LIGHT AND DYE LEAK DIAGNOSIS METHOD

Holden strongly recommends the use of the black light and dye method to diagnose fluid leaks. This method of leak

detection is a proven, reliable method that identifies the specific leak source and/or location. The black light kit is

suitable for various types of leak detection, when used with the appropriate tracer dye and can be used for detecting

engine coolant, engine oil, transm ission fluid, and air conditioning refrigerant leaks. The following is a summary of the

steps involved in detecting a cooling system fluid leak using black light and dye.

Important: Adding dye to the GEN III V8 engine cooling system, may change the colour of the coolant from an

orange colour to green. As the use of DEX-COOL® (to GM Specification 6277M) to this cooling system is

mandatory and is not to be mixed with other composition coolants, the green colour could be misleading for

future top-up operations.

Therefore, should the coolant change colour when the leak detection dye is added, then the cooling system

MUST be drained and new DEX-COOL® ( to GM Sp ecification 6277M ) coolant added . Refer 2.3 DRAINING AND

FILLING COOLING SYSTEM, in this Section.

1. Pour specified amount of dye into the coolant recovery surge tank. Refer 2.1 SAFETY NOTES in this Section.

2. Road test the vehicle under normal operating conditions.

3. Direct the blac k light towards the suspec t area. Any fluid leak will appear as a br ightly coloured path leading to the

source.

4. Repair fluid leak and recheck to ensure that leak has been rectified.

5. Refer to the manufacturer’s directions when using this method.

4. SPECIFICATIONS

RADIATOR CAP PRESSURE RATING..................... 100 kPa

COOLING SYSTEM CAPACITY................................ 12 Litres

COOLANT CORROSION INHIBITOR ....................... DEX-COOL® to GM Specification 6277M, approx. 6.0 litres

required when changing coolant.

THERMOSTAT

Type ........................................................................ Power element (wax pellet)

Start to open at........................................................ 86° C

Fully open at............................................................ 100° C

COOLANT PUMP

Type ........................................................................ Centrifugal

Drive........................................................................ Multi-ribbed, Serpentine V-belt

Bearing Type........................................................... Double-row ball bearing

RADIATOR

Core type................................................................. Aluminium crossflow core

Plastic tanks............................................................ Nylon 6,6

RADIATOR HOSES

Lower

Number and type................................................ Two, Moulded

Upper

Number and type................................................ One, Moulded

ENGINE COOLING FAN (1)

Number of blades.................................................... 5

Spacing ................................................................... Uneven

Material.................................................................... Polypropylene (20% glass filled)

Diameter.................................................................. 340 mm

Electric motor drive ................................................. 200 watts (nominal)

ENGINE COOLING FAN (2)

Number of blades.................................................... 7

Spacing ................................................................... Uneven

Material.................................................................... Polypropylene (20% glass filled)

Diameter.................................................................. 300 mm

Electric motor drive ................................................. 160 watts (nominal)

SEALANT

Cooling fan to motor shaft thread............................ Loctite 242 or equivalent (GM P/N 12345382)

Techline

5. TORQUE WRENCH SPECIFICATIONS

Engine Accessory Drive Belt Tensioner Bolt ........................ 40 - 60

Cooling Fan and Shroud to Radiator Attaching Bolt ............. 3.0 - 4.5

Coolant Pump to Cylinder Block Bolts Stage 1.................... 15

Stage 2.................... 25

Coolant Pump Pulley Attaching Bolts Stage 1.................... 10

Stage 2.................... 25

Coolant Pump Rear Cover Bolts........................................... 13 - 15

Fan Motor to Shroud Screw.................................................. 2.7 - 5.0

Fan to Motor Shaft Attaching Nut.......................................... 5.0 - 7.5

Oil Cooler to Side Tank Flared Nut Fitting............................ 20

Oil Pan Under-Tray Bolts...................................................... 30 - 35

Thermostat Housing to Coolant Pump Bolts......................... 13 - 15

6. SPECIAL TOOLS

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

AU435 COOLING SYSTEM HYDROMETER Previously released.

AU525 QUICK CONNECT RELEASE TOOL

U525

New release.

Use to release the quick

connect fittings on the

automatic transmission fluid

cooler lines at the radiator end,

when the vehicle is so

equipped.

J 24460-92 COOLING SYSTEM TEST ADAPTERS

New release.

Used to pressure test the

screw-on cooling system

pressure cap and the cooling

system.

J 26568 REFRACTOMETER

Previously released, also under

the number, AU435.

N/A COOLING SYSTEM PRESSURE TESTER

Commercially available.

Used in conjunction with

adapters J 24460-92