SECTION 6B1 - ENGINE COOLING -
V6 ENGINE
IMPORTANT
Before perfo rming any Service O peration or oth er procedu re described in t his Sectio n, refer to Section 00
CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.
1. GENERAL INFORMATION
2. GENERAL DESCRIPTION
2.1 RADIATOR
2.2 COOLING FANS
GENERAL DESCRIPTION
OPERATION
3. SERVICE OPERATIONS
3.1 SERVICE NOTES
3.2 COOLANT HOSES
3.3 RADIATOR
REMOVE
REINSTALL
3.4 COOLING FAN AND SHROUD ASSEMBLY
REMOVE
REINSTALL
DISASSEMBLE
REASSEMBLE
4. SPECIFICATIONS
5. TORQUE WRENCH SPECIFICATIONS
6. SPECIAL TOOLS
Techline
Techline
1. GENERAL I NFORMATION
The cooling system for VX, VU and WH Series II Models fitted with a V6 engine carries over from VX Series I
Models, NOTING THE FOLLOWING:
• A new condenser, radiator and fan module (CRFM) was introduced into WH Series II Models as a running
change during August 2002.
The inf ormation provided in this Section only applies to WH Ser ies II Models fitted with the revised cooling system.
For information regarding either the earlier type cooling system or the unchanged portion of the revised cooling
system, refer to Section 6B1-1 ENGINE COOLING - V6 ENGINE in the VX Series I Service Information in
conjunction with Section 6B1-1 ENGINE COOLING - V6 ENGINE in the VT Series I and VT Series II Service
Information.
With the revised system, two, single s peed electric cooling fans are m ounted on the shr oud, that is attached behind
the radiator. W hen operating on stage 1, only the left (larger) fan motor is enabled. W hen stage 2 is required, the
right (smaller) fan is also activated. For stage 1 then, only one fan motor is operational but for stage 2, both fan
motors operate.
Operation of the cooling fans is dependent on engine coolant temperature, vehicle speed, A/C request and A/C
system pressure.
The type of coolant used is dependent on vehicle specification. As requirements can change, always refer to the
WH Series II Owners Handbook for specific information regarding the particular vehicle being serviced. As both
coolant types are discussed in this Section, refer to the coolant applicable.
2. GENERAL DESCRI PTI O N
2.1 RADIATOR
The radiator utilises an alum inium core and is of the crossflow design, with a radiator cap located on the lef t-hand
side tank. Plas tic s ide tank s are attac hed to the c ore by the use of clinc h tabs . T he c linc h tabs ar e f or med as part of
the core assembly.
A high temperature rubber seal is used to seal the mating surface between the core and each side tank. The seal(s)
must be replaced any time a side tank is removed from the core.
IMPORTANT: T he radiator core s ide tanks or transm ission oil cooler CANNOT be r eplaced separately. If there is a
fault with any of these components, the radiator assembly must be replaced. Small core repairs may be made,
using an Aluminised Silicon based liquid repair agent.
For vehicles with automatic tr ansm iss ion, a transm is sion oil cooler is located in the lef t hand side radiator tank. T he
cooler pipes fr om and to the transm ission ar e connected to the oil cooler f lexible hoses by means of quick c onnect
fittings.
When air conditioning is fitted, the air conditioning condenser is mounted, by means of clips and brackets, to the
front of the radiator. The air conditioning receiver drier also forms a part of the complete assembly.
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.
2.2 COOLING FANS
GENERAL DESCRIPTION
Two, single speed, engine cooling fan m otors are used. The right fan is 268 mm in diameter with a motor rated at
120 Watts, while the left fan is 370 mm in diameter with a motor power rating of 160 Watts.
With 12 volts applied and the fans mounted to the radiator with a condenser fitted, the operating speeds are:
Stage 1 Stage 2
Large Fan 1,900 ± 150
rpm 1,900 ± 150
rpm
Small Fan Inoperative 2,350 ± 150
rpm
Figure 6B1-1
Legend
1. Fan Shroud
2. Radiator
3. Fan Shroud Lower Support
4. Fan Shroud Upper Support/Locking Retainer
5. Left Fan – 8 Blade, 370 mm Diameter
6. Left Fan Motor – 160 Watt, Single Speed
7. Left Fan Motor Securing Screws (3 places)
8. Left Fan Harness Connector(2 terminal)
9. Power Steering Reservoir Mount
10. Left and Right Fan Harness Connector (4 terminal)
11. Right Fan – 8 Blade, 268 mm Diameter
12. Right Fan Motor – 120 Wa tt, Single Speed
13. Right Fan Motor Securing Screws (3 places)
14. Automatic Transmission Cooling Line Retaining Clips
OPERATION
On WH Series II models with V6 engines and standar d specif ic ation fan m otor s , the engine cooling fan motors have
two term inals; one positive and one negative. The pos itive terminals ar e permanently connected to battery voltage,
via fusible links F101 (left fan) and F107 (right fan).
W hen the negative term inal is connected to gr ound
through the low speed cooling f an relay (1 ), the low
speed cooling fan (left) will operate. When the
negative term inal is connected to earth via the high
speed cooling fan relay (2), both cooling fans will
operate.
The low speed cooling fan operation is enabled
when the low speed engine cooling fan micro relay
(located in the underhood electrical centre) is
energised by the Body Control Module (BCM) via a
request from the Powertrain Control Module (PCM).
The PCM will request low speed fan enable or
disable, via the serial data Normal Mode Message
to the BCM on circuit 800 (Red/Black wire). After
the PCM requests a change in the state of the low
speed relay (i.e. OFF to ON or ON to OFF), the
BCM will send a serial data response message
back to the PCM confirming it received the
message.
Should a response from the BCM fail to occur, a
DTC P1064, will set.
Figure 6B1-2
The PCM determ ines when to enable the low speed fan relay based on inputs from the A/C request signal, Engine
Coolant Temperature (ECT) sensor and the Vehicle Speed Sensor (VSS).
There are also suppression capacitors incorporated into the fan motor, located on the brush holders. These
suppression capacitors help eliminate fan motor noise through the radio speakers. As these capacitors are not
serviced separately, should a problem occur with either capacitor, then the motor assembly must be replaced.
STAGE ONE FAN OPERATION
1. The low speed cooling fan relay will be turned ON when:
• Air conditioning request indicated (YES) and the vehicle speed is less than 30 km/h or:
• Air conditioning pressure is greater than 1,500 kPa or:
• Coolant temperature is greater than 104°C or:
• An engine coolant temperature sensor failure is detected by the PCM.
• When the ignition s witch is turned f r om ON to OF F and the engine c oolant temper ature is above 117°C, the
BCM will continue to energise the low speed engine cooling fan micro relay for approximately four minutes.
2. The PCM will request the BCM to s witch off the low speed c ooling fan relay when the following conditions have
been met:
• Air conditioning request not indicated (NO) and the coolant temperature is less than 99°C or:
• Air conditioning request indicated (YES) with pressure less than 1,170 kPa, vehicle speed greater than 50
km/h and coolant temperature less than 99°C.
STAGE TWO FAN OPERATION
The PCM determines when to enable the high speed fan relay based on inputs from the ECT sensor.
1. The high speed cooling fan relay will be turned ON if the low speed cooling fan relay has been energised for
one second and the following conditions have been met:
• If there is a BCM message response fault, setting a DTC P1064 or:
• An engine coolant temperature sensor failure is detected by the PCM, or:
• Engine coolant temperature is above 108°C or:
• Air conditioning pressure is greater than 2,000 kPa.
NOTE: If the low speed cooling fan is off when the criteria for turning the high speed cooling fan on are first
met, the high speed cooling fan will turn on 5 seconds after the low speed cooling fan is switched on.
2. If both the high and low speed cooling fans are enabled, the PCM will turn the high speed cooling fan OFF
when:
• The engine coolant temperature is less than 103°C and:
• Air conditioning request is not indicated (NO) or:
• Air conditioning request is indicated (YES) and the pressure is less than 1,500 kPa.
3. SERVICE OPERATIONS
3.1 SERVICE NOTES
CAUTION: To avoid serious personal injury, never remove the radiator cap or open the air vent valve on the
coolant outlet when the engine is hot, even if the cooling system should require filling. Sudden release of
cooling system pressure is very dangerous.
1. Before removing the radiator cap, allow the engine to cool, then place a shop rag over the radiator cap and
slowly turn the cap anti-clockwise, without pressing down until the cap reaches the first 'stop'. This is the
pressur e relief stop, which will allow any rem aining press ure within the system to escape. T hen press down on
cap and continue to rotate the cap anti-clockwise until it can be removed.
2. The vehicle is fitted with radiator electric cooling fans. W hen working around the engine compartm ent with the
engine running or with the ignition ON, keep clear of the fan as it may start operating without warning.
3. The cooling system requires little care except for maintaining the coolant at the correct level in the recovery
reservoir and periodic servicing at the time or distance intervals as outlined in the WH Series II Owner's
Handbook.
Periodic servicing includes:
a. Checking coolant level, refer to 2.3 CHECKING AND FILLING COOLING SYSTEM in Section 6B1-1
ENGINE COOLING – V6 ENGINE in the VT Series I Service Information.
b. Checking coolant concentration, refer to 2.2 GLYCOL COOLANT MAINTENANCE – Testing Coolant
Concentration in 6B1-1 ENGINE COOLING – V6 ENGINE in the VT Series I Service Information.
c. Pressure test cooling system and radiator cap, refer to 2.7 PRESSURE TESTING in 6B1 ENGINE
COOLING – V6 ENGINE in the VT Series I Service Information.
d. Tighten hose clam ps and inspect all hoses , refer to 3.2 COOL ANT HOSES in this Section. Replace hoses
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.
e. Clean out the cooling system, r efer to 2.4 CLEANING COOLING SY STEM – COOLING SYSTEM FLUSH,
in Section 6B1-1 ENGINE COOLING – V6 ENGINE in the VT Series I Service Information and refill the
cooling system, refer to 2.3 CHECKING AND FILLING COOLING SYSTEM in Section 6B1-1 ENGINE
COOLING – V6 ENGINE in the VT Series I Service Information.
4. To reduce environmental impact and maintenance cost, whenever the coolant is drained from any engine, the
service r ecor ds are to be c hec k ed to deter mine when the coolant was last c hanged. If mor e than six months life
is left before the next coolant change, then the following procedure is to be followed:
a. When draining the coolant from the engine, use a clean container of at least 15 litres capacity and ensure
that the coolant is not contaminated in the draining process.
b. After repairs have been completed, refill the engine cooling system with the drained coolant.
c. Top up as required, using a 50/50 mix of clean water and the recommended coolant, which is ‘New Formula
Long Life All Seasons Coolant’ (to HN2043 Specification or equivalent). Refer to 2.2 GLYCOL COOLANT
MAINTENANCE in Section 6B1-1 ENGINE CO OLING – V6 ENG INE in the VT Series I Servic e Inform ation
and 2.3 CHECKING AND FILLING COOLING SYSTEM in Section 6B1-1 ENGINE COOLING – V6
ENGINE in the VT Series I Service Information, for the necessary procedures and further information.
3.2 COOLANT HOSES
Coolant hoses are installed as shown in the following illustrations, taking note that there are a number of variants,
depending on a specific vehicle specification.
Hose connections should be thoroughly cleaned before installing any new hose.
After all hoses are fitted, always refill the cooling system with the correct concentration of coolant, refer to
2.3 CHECKING AND FILLING COOLING SYSTEM in Section 6B1-1 ENGINE COOLING – V6 ENGINE in the VT
Series I Service Inf ormation and pr essure test cooling s ystem , r efer to 2.7 PRESSURE TESTING in Sec tion 6B1-1
ENGINE COOLING – V6 ENGINE in the VT Series I Service Information.
CAUTION: Always wear protective safety glasses when working with spring type hose clamps. Failure to do
so could result in eye injury.
Legend (For Figure 6B1-3)
1. Coolant Recovery Tank Attaching Bolts (3 places)
2. Coolant Recovery Tank
3. Hose Clamp – Upper Hose to Engine Outlet
4. Upper Radiator Hose
5. Hose Clamp – Lower Hose to Radiator Outlet
6. Hose Clamp – Lower Hose to Engine Front Cover
7. Hose Clamp – Upper Hose to Radiator Outlet
8. Lower Radiator Hose
ENGINE COOLING SYSTEM HOSES
Figure 6B1-3
HEATER AND VACUUM HOSES
Figure 6B1-4
Legend
1. Heater Coolant Valve
2. Coolant Valve Actuator
3. Heater Hose to Cabin
4. Heater Hose from Cabin
5. Vacuum Hose – HVAC Supply
6. One-Way Check Valve
7. Vacuum Hose to Intake
Manifold
8. Heater Hose to Engine
9. Heater Hose from Engine
10. Vacuum Hose from Internal Control
11. Heater Core Hose Clamps
(2 places)
12. Vacuum Hose – Coolant Valve
Actuator
13. Brake Booster
14. Steering Shaft
15. Brake Hydraulic Pipes
16. Coolant Valve Hose Clamps
(4 places)
17. Wheel House RHS
18. Mounting Clip for Heater Coolant
Valve
19. Hose Clamps to Engine (2 places)
NOTE: Heater and vacuum hoses to be routed under brake hydraulic pipes. Refer view B
3.3 RADIATOR
REMOVE
1. Allow engine to cool to ambient temperature
(less than 50°C), then, remove the radiator
cap.
CAUTION: Do not remove the radiator cap while
the engine coolant temperature is above 50°
°°
°C,
as personal injury may result.
2. Disconnect the battery ground lead.
IMPORTANT: Disconnection of the battery affects
certain vehicle electronic systems. Refer to
BATTERY DISCONNECT CAUTION in Section 00
CAUTIONS AND NOTES in the VX Series II Service
Information before disconnecting the battery.
3. Remove the c oolant overflow hose (1) f rom the
radiator filler neck connection.
Figure 6B1-5
4. Remove the radiator lower hose (2) from the
radiator connection, allowing the coolant to
drain into a suitable sized and clean drain tray.
IMPORTANT: Ref er to item No. 4 in 3.1 SERVICE
NOTES in this Section regarding the collection of
the drained coolant.
CAUTION: Always wear protective safety
glasses when working with spring type hose
clamps. Failure to do so could result in eye
injury.
5. Remove the radiator upper hose (1) from the
radiator.
Figure 6B1-6
6. Remove the cold air intake duct and radiator
shroud retainer s (1 and 2) . Remove the cold air
intake duct (2), then disengage the shroud
locating tabs (5) by pulling the shroud (4)
towards the front of the vehicle, prior to
removal.
7. Disconnect the retainer clip securing the high
pressure air conditioning pipe to the top of the
front upper panel assembly on the left-hand
side.
Figure 6B1-7
NOTE: T he condens er mus t be separated f rom the
radiator ass embly. This ac tion will allow the radiator
removal without having to open any refrigerant
lines.
8. Wor king through the grille opening, release one
of the clips securing the condenser to the
radiator (bold arrow) by pressing down on the
lug while lifting the condenser assembly.
Repeat for the other side.
9. Once released, pull the condenser assembly
forward to clear the radiator mounting lugs.
Figure 6B1-8
10. Disconnect the transmission oil cooler line
quick connect fittings, using Tool No. AU525:
a. Open release tool AU525, then close and
clip around the pipe to be disconnected.
b. While holding the flexible hose with one
hand, push the tool into connection (1), to
release, then pull back on the pipe (2).
c. Plug all openings to minim ise fluid loss and
prevent dirt entry.
Figure 6B1-9
NOTE: If Tool No. AU525 is not available, the
cooler pipes can be disconnected from the cooler,
in the left side radiator tank using the following
method:
d. Using a suitable set spanner, loosen the
cooler pipe tube nut (1), then remove,
taking care not to lose the sealing washer
(3). Plug both open ends to prevent fluid
loss and/or dirt entry.
e. Repeat for the second pipe/hose assembly.
f. Before installing each pipe (2) into the
cooler, carefully inspect the pipe sealing
washer (3). If the centre, silicone portion
shows s igns of dis tress or dam age, it must
be replaced.
g. Remove the plugging from the pipe and
fittings, fit the sealing washer (3) to the
cleaned pipe (2) and install into the cooler.
h. Install the tube nut (1) and tighten to the
correct torque specification.
Figure 6B1-10
11. Depress the tang on the main wiring harness-
to-cooling fan motor wiring harness connector
(1) and separate the connector.
Figure 6B1-11
12. Using a screwdriver, compress and lever out
the radiator retaining clips (1) from the radiator
upper mounting brackets.
13. Lift the radiator upwards out of the lower
insulators and remove the radiator from the
vehicle.
IMPORTANT: If removing the fan and shroud as
an assembly to the radiator, do not use the fan
outer rings, as lifting devices, as this will bend the
fan motor shafts causing unnecessary vibration,
when the vehicle is placed back in service.
14. Remove the upper (2) and lower insulators
from the radiator.
15. If required, separate the fan and shroud
assembly from the radiator by releasing the two
locking tangs at the upper locations, then slide
the fan shroud up and clear from the radiator.
Figure 6B1-12
REINSTALL
Installation of the radiator is the reverse of the
removal procedures, noting the following points:
1. Before installing the radiator, inspect the core
to ensure that there is no foreign matter in the
core fins. Clean out between the core fins with
compressed air, blowing from the rear to the
front.
2. Ensure that the radiator lower mounting pins
are correctly located in the lower insulators.
3. Ensure that the upper insulators are installed
on the upper mounting pins and the radiator
retainers are installed.
4. Install the radiator upper shroud (3) by first
locating each of the two locating tabs (4), then
securing with four plastic fasteners (2).
5. Install the cold air intake duct, securing with
two plastic fasteners (1).
Figure 6B1-13
6. Refill the cooling system, refer to
2.3 CHECKING AND FILLING COOLING
SYSTEM in Section 6B1-1 ENG INE CO OLING
– V6 ENGINE in the VT Series I Service
Information.
7. Check for coolant leaks, refer to
2.7 PRESSURE TESTING in Section 6B1-1
ENGINE COOLING – V6 ENGINE in the VT
Series I Service Information.
8. Check the cooling fan operation, including the
fan rotation direction.
3.4 COOLING FAN AND SHROUD ASSEMBLY
REMOVE
1. Disconnect the battery ground lead.
IMPORTANT: Disconnection of the battery affects
certain vehicle electronic systems. Refer to
BATTERY DISCONNECT CAUTION in Section 00
CAUTIONS AND NOTES in the VX Series II Service
Information before disconnecting the battery.
2. Depress the tang on the main wiring harness-
to-cooling fan motor wiring harness connector
and separate the connector.
Figure 6B1-14
3. Remove the power steering pump reservoir
from its clip on the radiator shroud, using a
screwdriver to lever the clip lock, enabling
removal of the reservoir. Lay the reservoir and
hoses to one side.
Figure 6B1-15
4. Release each of the automatic transmission
cooling pipes from the integral clips on the fan
shroud.
Figure 6B1-16
Techline
5. Release the fan shroud-to-radiator clips by
holding one of the lugs (1) out with the fingers
of one hand while lifting the shroud with the
other. Repeat this operation to release the
second side.
Figure 6B1-17
6. Lift the fans and shroud assembly from the
engine bay.
Figure 6B1-18
IMPORTANT: When rem oving, transpor ting or installing the f an ass em bly, do not grasp the assem bly by the fan
rings (1) as this may bend the fan motor shafts and cause fan vibrations.
Figure 6B1-19
When handling the fan assembly, always hold the assembly at the fan shroud (1) or fan motor mounting
struts (2).
Figure 6B1-20
REINSTALL
Installation of the cooling fan and shroud assembly is the reverse of removal procedures, noting the following points:
1. Ensure that the fan and shroud assembly to radiator attaching clips are fully engaged.
2. Ensure that both the automatic transmission cooling pipes (if fitted) are installed to the shroud clips.
3. Check the cooling fan operation, including the fan rotation direction.
DISASSEMBLE
1. Remove the cooling fan and shroud assembly as previously described.
IMPORTANT: Neither of the fans (2) are to be
separated from the fan motor. The assembly is
carefully balanced during manufacture and,
duplicating this balance on reassembly, is not
possible.
1. Remove the motor as sembly wiring harness (1)
from the integral clips that form a part of the
shroud (3).
NOTE: Separate the intermediate wiring harness
connector (5).
2. Remove the screws (4) attaching the motor
assembly to the shroud (3), then remove each
motor, fan and wiring from the shroud.
Figure 6B1-21
REASSEMBLE
Reassembly is the reverse of disassembly procedures, noting the following points:
1. Tighten the motor-to-shroud attaching screws securely but do not over-tighten.
2. Install the motor wiring harness into the shroud attaching clips. Install the intermediate connector.
3. Reinstall the cooling fan and shroud assembly as previously described.
4. SPECIFICATIONS
General
Radiator cap pressure rating................................... 135 kPa
Cooling system capacity.......................................... 12 Litres
Coolant corrosion inhibitor....................................... 'New Formula Long Life All Seasons Coolant'
Thermostat
Type ........................................................................ Power element (wax pellet)
Start to open............................................................ 89° – 93°C
Fully open at............................................................ 106°C max
Coolant Pump
Type ........................................................................ Centrifugal
Drive........................................................................ Multi-Vee Serpentine Belt
Bearing ty pe............................................................ Double Row Ball Bearing
Radiator
Core type................................................................. Aluminium crossflow core
Overall width (including side tanks)......................... 847 mm
Core width............................................................... 674 mm
Overall height.......................................................... 507 mm
Core height.............................................................. 430.5 mm
Core thickness ........................................................ 16 mm
Plastic tanks............................................................ Nylon 6,6 (30% Glass filled)
Radiator Hoses
Lower
Number and type................................................ One, Moulded
Inside diameter................................................... 38.5 mm
Upper
Number and type................................................ One, Moulded
Inside diameter................................................... 34.0
Small Engine Cooling Fan (Right)
Number of blades.................................................... 8
Spacing ................................................................... Symmetrical
Material.................................................................... Nylon 6,6 (25% Glass filled)
Diameter.................................................................. 268 mm
Electric motor drive ................................................. 120 Watts (nominal)
Speed (with 12 volts applied, Radiator and
Condenser installed – Stage 1 ........................ OFF
– Stage 2 ........................ 2,350 ± 150 rpm
Large Engine Cooling Fan (Left)
Number of blades.................................................... 8
Spacing ................................................................... Symmetrical
Material.................................................................... Nylon 6,6 (25% Glass filled)
Diameter.................................................................. 370 mm
Electric motor drive ................................................. 160 Watts (nominal)
Speed (with 12 volts applied, Radiator and
Condenser installed – Stage 1 ........................ 1,900 ± 150 rpm
– Stage 2 ........................ 1,900 ± 150 rpm
5. TORQUE WRENCH SPECIFICATIONS
Nm
Coolant Hose Clamps........................................................... 3
Engine Dress Cover Attaching Nut....................................... 5
Rear Engine Cover Bracket Assembly Securing Bolts ......... 18
Oil Cooler To Side Tank Nut................................................. 25
Oil Cooler Pipe to Oil Cooler................................................. 25
6. SPECIAL TOOLS
TOOL
NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION
AU525
A
U525
QUICK CONNECT RELEASE
TOOL
Used to release the quick connect
fittings on the automatic
transmission fluid cooler lines at
the radiator end, when the vehicle
is so equipped.
Previously released.
Mandatory