SECTION 6B3 - ENGINE COOLING –

GEN III V8 ENGINE

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL INFORMATION

1.1 GENERAL DESCRIPTION

RADIATOR

COOLING FANS

COOLANT PUMP

THERMOSTAT

SCREW-ON PRESSURE CAP

COOLANT SURGE TANK

VAPOUR VENT SYSTEM

AIR BAFFLES AND DUCTS

COOLANT TEMPERATURE SENSOR

2. SERVICE OPERATIONS

2.1 SERVICE NOTES

SAFETY

PERIODIC SERVICING

ENVIRONMENTAL ISSUES

2.2 COOLANT MAINTENANCE

TOPPING UP THE COOLING SYSTEM

TESTING COOLANT CONCENTRATION

2.3 DRAINING AND FILLING COOLING SYSTEM

DRAINING

FILLING

2.4 COOLANT HOSES

2.5 CLEANING COOLING SYSTEM

COOLING SYSTEM REVERSE FLUSH

2.6 ENGINE ACCESSORY DRIVE BELT TENSION

2.7 ENGINE ACCESSORY DRIVE BELT

REMOVE

INSPECT

REINSTALL

2.8 PRESSURE TESTING

SCREW-ON PRESSURE CAP TESTING

COOLING SYSTEM PRESSURE TESTING

2.9 THERMOSTAT

REMOVE

TEST

DISMANTLE

REASSEMBLE

REINSTALL

2.10 COOLANT RECOVERY SURGE TANK

REMOVE

INSPECT

REINSTALL

2.11 ENGINE COOLANT LEVEL SWITCH

REMOVE

INSPECT

REINSTALL

2.12 OIL PAN UNDER-TRAY

REMOVE

REINSTALL

2.13 AIR BAFFLES

REPLACE

2.14 COOLANT PUMP

REMOVE

DISMANTLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

2.15 COOLING FANS & SHROUD ASSEMBLY

REMOVE

DISASSEMBLE

REASSEMBLE

REINSTALL

2.16 RADIATOR

REMOVE

REINSTALL

RADIATOR REPAIR PROCEDURE9

3. ENGINE COOLING SYSTEM DIAGNOSIS

3.1 ENGINE OVERHEATING

3.2 L OSS OF COOLANT

3.3 ENGINE FAILS TO REACH NORMAL OPERATING

TEMPERATURE

3.4 BLACK LIGHT AND DYE LEAK DIAGNOSIS

METHOD

4. SPECIFICATIONS

5. TORQUE WRENCH SPECIFICATIONS

6. SPECIAL TOOLS

Techline

1. GENERAL INFORMAT ION

The c ooling system f or MY 2003 V Y and V 2 Seri es vehicles wit h the G EN II I V8 e ngi ne, co ns is ts of t wo, two-s peed

electric cooling fans 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 for further information.

1.1 GENERAL DESCRIPTION

RADI ATOR

The radiator (1) is of the crossflow design and consists of an aluminium core with plastic side tanks attached to

each end of the c ore. For vehicl es with autom atic transmiss ion, a transmiss ion oil cooler is loca ted in the left hand

side tank.

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 and/or transm ission oil cooler CANNO T be replaced separ ately. If there is a f ault with

any of these components, the radiator assembly must be replaced. Small core repairs can be made using an

Aluminised Silicon based liquid repair agent, refer to RADIATOR REPAIR PROCEDURE, in 2.16 RADIATOR, in

this Section.

COOLING FANS

The cooling system for the GEN III V8 engine, includes two, double speed, engine cooling fan motors, both of

which, drive fans with five, asymmetrical blades, to reduce air noise. The larger, right fan is 342 mm in diameter

and has a m otor rated at 2 20 Watts , while the sm aller, left fan is 29 3 mm in diam eter with a m otor power rat ing of

180 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 2,350 ± 150

rpm 2,750 ± 150

rpm

Small Fan 2,050 ± 150

rpm 2,300 ± 150

rpm

Figure 6B3-1 – Cooling Fans, GEN III V8

Legend

1. Fan Shroud

2. Radiator

3. Fan Shroud Lower Support

4. Fan Shroud Upper Support/Locking Retainer

5. Small, Left Fan – 5 Blade, 293 mm Diameter

6. Small, Left Fan Motor – 180 Watt, Double Speed

7. Left Fan Motor Harness Connector (3 Terminal)

8. Left and Right Fan Motor Harness Connector (5 terminal)

9. Large, Right Fan – 5 Blade, 342 mm Diameter

10. Large, Right Fan Motor – 220 Watt, Double Speed

11. Oil Cooler, Lower Quick Connect Fitting (Auto. Trans Only)

12. Oil Cooler, Upper Quick Connect Fitting (Auto. Trans Only)

Operation

To achieve the dual speed requirement, the e lectrical circuitry for the GEN III V8 each of the cooling fans has two

negative and one positive terminal. To reduce the heat burden on the electrical connectors, the current draw is

directed through separate negative terminals at the jo int connector (‘8’ in Figure 6B3-1), for each f an motor, when

operating on low speed. When operating at high speed, only one negative terminal is required.

The positive terminals are permanently connected

to battery voltage, via fusible links F101 (large fan)

and F107 (small fan).

The eng ine c oo li ng f an r ela y 1 ( R7) is e nerg is ed by

the BCM. When the PCM determines that the

engine cooling fan relay 1 should be enabled, the

PCM will send a message on the Class 2 serial

data circuit to the PIM. The PIM will then convert

the PCM Class 2 message to a UART message

and supply this UART message to the BCM, via a

serial data Normal Mode Message to the BCM on

circuit 800 (Red/Black wire). This message will

request the BCM to supply the needed ground

signal for the engine cooling fan relay 1 to operate.

After the BCM provides the ground signal for the

engine cooling fan relay 1, the BCM will send a

message back to the PIM confirming that the

ground signal was commanded.

Figure 6B1-2 – Underhood Fuse & Rela y Centre

A failure in this BCM response communication, will cause a PIM DTC B2002 to set.

The PCM determines when to enable stage 1, 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

The engine cooling fan relay 1 (R7) will be turned ON when:

• The A/C request indicated (YES) and either:

• the vehicle speed is less than 30 km/h.

• A/C pressure is greater than 1500 kPa

• The coolant temperature is greater than 98° C.

• or

• If the coolant temperature is greater than 113° C, when the ignition is switched off, the relay is energised

for approximately four minutes, this is known as Low Fan Run On.

• or

• If an engine c oola nt temperatur e s ensor f ault is det ec ted and a DT C s uc h as DTC P011 7, P 011 8, P1 114 or

P1115 is set.

The engine cooling fan relay 1 will be turned OFF when any of the following conditions have been met:

• An A/C request is not indicated (NO) and the coolant temperature is less than 95° C.

• An A/C requ est is indicate d ( YES) a nd the ve hicle s peed is greater than 50 k m /h and A/C press ure is les s th an

1,170 kPa and the coolant temperature is less than 98° C.

Stage Two Fan Operation

The engine cooling fan relay 2 (R5) is controlled by the PCM. The PCM will only activate stage 2 fan operation, if

the engine cooling fan relay 1 has been “ON” for two seconds and the following conditions are satisfied.

• There is a BCM message response fault which will cause a PIM DTC B2002.

• An eng ine coolant t emperature sens or fault is d etected and a DT C such as DTC P01 17, P0118, P 1114 or

P1115 is set.

• Coolant temperature greater than 108° C.

• The A/C refrigerant pressure is greater than 2400 kPa.

If the e ngine cool ing fan re lay 1 was OFF when the cr iteria was met to ac tivate e ngine co oling fan r ela y 2, stage 2

fan operation will occur, 5 seconds after the engine cooling fan relay 1 is turned ON. If both engine cooling fan

relays are ON, the PCM will turn OFF engine cooling fan relay 2 when:

• The engine coolant temperature is less than 102° C.

• A/C request not indicated ( NO ).

• A/C request indicated (YES) and A/C pressure is less than 1900 kPa.

NOTE: Both cooling fans will be turned off if the vehicle speed is greater than 104 km/h.

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 further details of the

engine coo ling fan operat ion and d iagnosis of the system , see Section 6C3 POW ERTRAIN MANAGEMENT – GEN III

V8 ENGINE.

COOLANT PUMP

The c oolant p um p (1) is m ount ed to th e fr ont of th e

cylinder b lock and is dri ven by the ser pentine 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 6B3-3

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

coolant pump housing.

The therm ostat is also located in the coolant pum p

housing, at the coolant inlet fitting (2).

Figure 6B3-4

THERMOSTA T

A wax pellet type therm ostat 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 el ement in t he 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

same r ate as the temper ature rise of the co olant in

the engine.

Figure 6B3-5

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

expands, causing the bras s body (1) to move back

into the sm aller 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 bod y, warming the wax ins ide 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 co mbined force exerted b y

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 6B3-6

SCREW-ON PRESSURE CAP

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 pres sure cap (1) c ontains a press ure 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 range of the cooling system

(from 96.5 – 124 kPa: nominal 103 kPa). The

vacuum valve (3) is held against its seat by a light

spring (6). T he vacuum created during coo lant 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 6B3-7

COOLANT SURGE TANK

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 pressu re hose from the h eater

connection at the coolant pump (2) and a vapour

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

As the engine tem perature rises, the coolant heats

and expands. The fluid displaced by expansion

flows into t he coolant sur ge tank. W hen the engine

is turned off, the coolant contracts as it cools and

the pressure in the surge tank returns to

atmo spheric, by the unseating of the vacuum valve

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

Coolant le vel sh ould be m ainta ined at t he indic ated

point on the side of the surge tank, when the

engine is cold, by sighting the level externally. A

coolant l evel switc h is insta lled in the sur ge tank to

alert the operator if the coolant level gets too low.

The cooling system is designed to use extended

life anti-freeze coolant (conforming to GM6277M)

in a concentration level of 50% extended life

anti-freeze coolant (conforming to GM6277M) 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.

Figure 6B3-8

CAUTION: Because the surge tank is

pressuris ed , th e temperatu re of th e coo lant c an

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.

VAPOUR VENT SYSTEM

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 vapour

vent pipe (1), fastened to the front of the cylinder

heads in two places, by double ended studs (2).

The rear locations are blocked by two vapour vent

covers (3). All four locations are sealed by gaskets

(4).

Vapour then flows via hoses, through the throttle

body, to the left hand radiator side tank. Another

vent hose t hen connects th e left hand rad iator side

tank with the coolant surge tank, thereby directing

vapour to that point.

Figure 6B3-9

A IR BAFFLES AND DUCTS

Air baffles and side chutes are fitted to the front end of the vehicle to direct and promote air flow through the

radiator to provide maximum cooling.

The purpos e of the air baf fles is to create a l ow pres sur e area behi nd the r adiator and a hig h press ure area in f ront

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 baffles or side chutes should never be removed unless for service work. If either the air baffles or side

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

Figure 6B3-10 – All GEN III V8 Except SS Models

Legend

1. Left Hand Side Air Chute (View ‘A’)

2. Right Hand Side Air Chute (View ‘B’)

3. Lower Front Air Chute Baffle (View ‘C’)

4. Fastener (4 places)

5. Lower Rear Air Chute Baffle

6. Screw (2 places)

All ‘SS’ pack vehicles (including Utility) have a front

air duct (1) fitted, in addition to the lower air chute

baffle (2), to concentrate more air flow through the

radiator core.

The two central ‘scrivets’ (3), secure both the air duct

and the chute baffle to the front crossmember.

Figure 6B3-11 – SS Models (Including Utility)

An oil pan under-tray (1) also forms an integral part

of the air flow system around the GEN III V8 engine

and must always be reinstalled after removal fo

service operations, such as engine oil draining and

oil filter replacement.

NOTE: This tray is not designed as an oil pan stone

guard.

Figure 6B3-12

n 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 o

the radiator back over the core.

Figure 6B3-13

COOLANT TEMPERATURE SENSOR

A coolant tem perature s ensor ( 1) is mounted in th e

front of the left hand cylinder head.

The c oolant tem peratur e s ensor ge nerates a signa l

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 temperatur e gauge function, on

the serial data bus.

Figure 6B3-14

2. SERVICE OPERATIONS

2.1 SERVICE NOTES

SAFETY

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

then slo wly turn the cap anti-c lockwise, to lo osen. DO NOT SPIN T HE CAP OFF! If there is any residu al pressur e

in the coo ling system , it can then be r eleased into t he dam under the cap and out through the dr ain hose onto the

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

CAUTION: TO AVOID SERIOUS PERSON AL IN JURY, NEVE R REM OVE THE SCREW-ON SURG E T ANK CAP

WHEN THE ENGINE IS HOT, EVEN IF THE COOLING SYSTEM SHOULD REQUIRE FILLING. SUDDEN

RELEASE OF COOLING SYSTEM PRESSURE IS VERY DANGEROUS.

The vehic le is fitte d with twin r adiator el ectric c ooling fans. W hen work ing around the engine c ompartm ent with the

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

PERIODIC SER VICING

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 TEST ING in this Section.

4. Check/tighten hose clamps and inspect all hoses, refer to 2.4 COOLANT 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.

5. Clean out cooling system, refer 2.5 CLE ANING COO LING SYSTEM , in this Sec tion and refill cooling s ystem ,

refer to 2.3 DRAINING A ND FILLING COOLING SYSTEM in this Section.

ENVIRONMENTAL ISSUES

To reduce the impact on the environment and the maintenance cost, whenever the coolant is drained from the GEN

III V8 engine, t he service records are to be check ed to determine when the coolant was last change d. If more than

six months life is left before the next coolant change, then the following procedure is to be adhered to:

1. W hen draining the coo lant from the engine, use a c lean container of at least 15 litres c apacity and ensure that

the coolant is not contaminated in the drai ni ng pr oces s .

2. After repairs have been completed, refill the engine cooling system with the drained coolant.

3. Top up as required , using a 50% m ixture of extended li fe anti- free ze coolant ( conf orm ing to GM6277 M) to 50%

clean, good qualit y water. Refer 2.2 COOL ANT M AIN TEN ANCE and 2.3 DR AINING AND FILLING COOLING

SYSTEM in this Section.

2.2 COOLANT MAINTENANCE

The c ooling system is designed to use a s pecif ic cool ant (a m ixture of extended lif e anti-f ree ze coolant (c onform ing

to GM6277M) 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 importance that the correct concentration level of extended life anti-

freeze coolant (conforming to GM6277M) 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 the extended life anti-freeze coolant (conforming to GM6277M) become ineffective.

The coolant should comprise of a mixture 50% extended life anti-freeze coolant (conforming to GM6277M) 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% extended life anti-freeze

coolant ( conform ing to GM6277M) with 50% c lean,

good qualit y water) m ay be added as necessary to

bring the level s ho wn on the c oolant su rge tank but

only when the engine is cold.

Figure 6B3-15

TESTING COOLANT CONCENTRATION

To ensure the specified ethylene glycol concentration is maintained in the engine coolant, the coolant concentration

must be checked at the time or distance intervals outlined in the MY 2003 VY and V2 Series 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 – Refractometer

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 measuring 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 few 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 6B3-16

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 ref er ence s c ale f or ex tende d lif e ant i-

freeze coolant (conforming to GM6277M).

NOTE: The temperature scale is reversed from

that of a conventional thermometer. Readings

below zero 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 s atis fac tory for the G EN

III V8 engine cooling system.

Figure 6B3-17

NOTE: If the reading is not clear, then properly

clean and dr y the m easuring s urface, 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, refer to the

following table to determine the amount of

extended life anti- fr eeze coola nt (c onforming to

GM6277M) that needs to be added to the

surge tank.

10. Start and run the engine u ntil norm al operatin g

temperature is reached, to allow the added

coolant to be distributed throughout the engine

cooling system.

Figure 6B3-18

CONCENTRATION

READING % LITRES OF

COOLANT TO BE

ADDED

0 7.2

5 6.8

10 6.3

15 5.8

20 5.3

25 4.7

30 4.1

35 3.4

40 2.6

45 1.5

50 0

Table 1

Calibrating the Tester

While the coolant tester calibration is checked at manufacture, if the calibration check detailed in step 1 of this

method shows that the instrument 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, Tool No. AU505 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

extended life anti- fr eeze coola nt (c onforming to

GM6277M).

Refer to the chart shown for the previous

method to determine how much extended life

anti-freeze coolant (conforming to GM6277M)

is required to add to the cooling system to

bring the coolant to the specified concentration.

5. Drain s ufficient quantit y of coolant f rom cooling

system to allow top-up with extended life anti-

freeze c oolant (conf orming to GM6277 M), then

add the required amount. Install screw-on

pressure cap.

6. Start and run th e engine un til norm al operating

temperature is reached, to allow the added

coolant to be distributed throughout the engine

cooling system.

Figure 6B3-19

2.3 DRAINING AND FILLING COOLING SYSTEM

DRAINING

CAUTION: To avoid the possibility of scalding, it is recommended that this operation is only carried out

when the engine is cold.

The recommended method of draining the G EN III V8 engine cooling system, is to remove the screw-on pr essure

cap from the surge tank, then remove the hose clamp from the radiator hose at the lower left hand radiator side

tank, dr aining the c oo li ng syst em contents into a s uit a ble c lean c ont ain er , with a c apac ity of at least 15 l itres. Refer

to ‘ENVIRONMENTAL ISSUES’, in 2.1 SERVICE NOTES, in this Section.

FILLING

As the GEN III V8 engine has a vapour pipe attached to each cylinder head, 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 7.2 litres of ex tended life anti- fr eeze coola nt (c onform ing to GM627 7M) with 7.1 litr es of c lean, good qua lity

water.

NOTE 1: Do not mix different t ypes of antifreeze or c orrosion inhibitors as the y m ay be incompatible. If a dif ferent

type has been used in the cooling system, flush the system with clean water, refer to 2.5 CLEANING COOLING

SYSTEM in this Section.

NOTE 2: When using extended life anti-freeze coolant (conforming to GM6277M) 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 T EST ING in this Section.

6. Reinstall the screw-on pressure cap to the

reservoir.

7. Start and run th e engine un til norm al operating

temperature is reached, at which time the

added quantity of extended life anti-freeze

coolant (conforming to GM6277M) will have

dispersed through the engine’s cooling system.

Figure 6B3-20

2.4 COOLANT HOSES

LT SECTION NO. – 01-160

1. Coolant hoses are installed as shown in the following illustrations.

NOTE: The engine cooling fans, motors and shroud are shown removed in Figure 6B3-20, to more clearly

show hose routing.

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

NOTE: Because of the productio n method of inst alling the sprin g type hose clam ps, access to the clamp ends

may not be possible. Particularly for the clamps securing the hoses to the lower bridging piece of the coolant

intake and coolant surge tank hoses, it may be necessary to remove the complete hose assembly from the

vehicle.

Figure 6B3-21 - Cooling System Hose Layout - GEN III V8 Engine – RHD and LHD Applications

Legend

1. Hoses – Heater

2. Hose – To Coolant Surge Tank 1 of 2

3. Hose – Radiator Lower 1 of 2

5. Hose – Radiator Upper

6. Bridging Pipe – Radiator Hoses

7. Hose – Radiator Lower 2 of 2

9. Hose – Vapour to Radiator

10. Hose – Vapour to Surge tank

11. Pump Coolant

4. Radiator 8. Hose – To Coolant Surge Tank 2 of 2 12. Housing – Thermostat

Figure 6B3-22 - Heater Hose Arrangement - GEN III V8 Engine – RHD Application

Legend

1. Coolant Valve

2. Coolant Valve Actuator

3. Heater Hose to Interior Heater Core

4. Heater Hose from Interior Heater Core

5. Vacuum Hose – HVAC Supply

6. One-Way Check Valve

7. Vacuum Hose to Intake Manifold

8. Heater Hose to Engine

9. Hose to Coolant Surge Tank

10. Heater Hose T-piece

11. Heater Hose to T-piece

12. Heater Hose from Engine

13. Vacuum Hose to Interior Control Valve

14. Heater Hose Clamps (2 places)

15. Vacuum Hose to Coolant Valve Actuator

16. Brake Booster

17. Steering Shaft

18. Brake Lines

19. Coolant Valve Hose Clamps (4 plac es)

20. Right Side Wheelhouse

21. Clip - Coolant Flow Control Valve

22. Heater Hose Clamps to Engine (2 places)

23. T-piece Hose Clamps (2 places)

24. T-piece Hose Worm Drive Clam p (1 place)

NOTE: Heater and vacuum hoses to be routed under Brake Pipes – refer View B

Figure 6B3-23 - Heater Hose Arrangement - GEN III V8 Engine – LHD Application

Legend

1. Coolant Valve

2. Coolant Valve Actuator

3. Heater Hose to Heater Core

4. Heater Hose from Heater Core

5. Vacuum Hose – HVAC Supply

6. One-Way Check Valve

7. Vacuum Hose to Intake Manifold

8. Heater Hose to Engine

9. Hose to Coolant Surge Tank

10. Heater Hose T-piece

11. Heater Hose to T-piece

12. Heater Hose from Engine

13. Vacuum Hose to Interior Control Valve

14. Heater Core Hose Clamps (2 places)

15. Vacuum Hose to Coolant Valve Actuator

16. Brake Lines

17. Coolant Valve Hose Clamps (4 plac es)

18. Right Side Wheelhouse

19. Clip - Coolant Flow Control Valve

20. Heater Hose Clamps to Engine (2 places)

21. T-piece Hose Clamps (2 places)

22. T-piece Worm Drive Hose Clamp (1 place)

NOTE: Heater and vacuum hoses to be routed under Brake Pipes – refer View B

2.5 CLEANING COOLING SYSTEM

NOTE: Before carrying out reverse flushing procedures, it is recommended that a cleaning solution be used to

loosen scale and corrosion. Use an approved radiator cleaner, such as 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 room

temperature.

When using specialised cooling system flushing equipment, only connect as recommended by the manufacturer.

1. Remove engine dress cover decorative nuts

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

Figure 6B3-24

Radiator:

1. Place suitable, clean, drain tray beneath vehicle.

2. Rem ove the screw-on pressure cap from the coolant surge tank, taking care to release any residual pressure

before fully removing.

3. Loosen the worm drive radiator hose clamp from the lower left hand side radiator tank, disconnect the hose and

drain 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 type hose clamps. Failure to

do so could result in eye injury.

Figure 6B3-25

6. Rem ove the vapour hos e to coolant s urge ta nk

connection at the radiator left hand tank.

7. Disconnect the vapour hose at the throttle body

(‘2’ in Figure 6B3-24 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 lo wer hose.

10. Connect and operate the flushing equipment

as recommended by the manufacturer.

IMPORTANT: App ly air pre ssure gr aduall y and not

in excess of 110 kPa. Otherwise radiator damage

will result.

11. Continue flushin g until the water from the lead-

away hose runs clear.

12. Reinstall all disconnected hoses, ensuring that

spring hose clamps are positioned correctly

and/or tightened.

Figure 6B3-26

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 PR ESSURE TE ST ING , in this Section.

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 s crap hose and two

hose clamps.

3. Fit a lead-awa y hose t o the therm os tat 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. Cont inue flushing unt il the water f rom the lead-

away hose runs clear.

6. Reinstall all disconnected hoses, ensuring that

hose clamps are positioned correctly and/or

tightened.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TYPE HOSE CLAM PS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

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.

Figure 6B3-27

Heater Hoses and Core:

1. It is assumed that the following have already been carried out:

a. The engine is at room 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 (1) from the rear

coolant pump fitting (spring type clamp) and

the other Hose (2) from the T-piece (worm

drive hose clamp), leaving the T-piece and

coolant surge tank hose still connected, as

shown.

4. Direc t the hose disconnec ted 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. Cont inue flushing unt il the water f rom the lead-

away hose runs clear.

7. Reinstall all disconnected hoses, ensuring that

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.

Figure 6B3-28

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 PR ES SUR E TE STING, in this Section.

Coolant Surge Tank and Hose:

1. It is assumed that the following have already been carried out:

a. The engine is at room 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 s ystem , refer to 2.8 PRESSU RE TEST ING in this Section a nd check for exter nal 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- load ed arm that m aintains th e

drive belt (2) at the correct tension, without

imposing undue loads on the various components.

Figure 6B3-29

Drive belt tension is within the prescribed limits if

the indicator (bold arrow) on the tensioner is

between points ‘A’ and ‘B’ on t he tensi oner brac ket

If replacement is indicated, refer to 2.7 ENGINE

ACCESSORY DRIVE BELT, in this Section.

Figure 6B3-30

2.7 ENGINE ACCESSORY DRIVE BELT

LT SECTION NO. – 01-003

REMOVE

1. Remove engine dress cover decorative nuts

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

Figure 6B3-31

2. Using a 15 mm ring spann er, rotate the engi ne

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 6B3-32

INSPECT

The four views in Figure 6B3-33 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.

Figure 6B3-33

Legend:

A New Belt: No cracks or chunks.

B Moderately Used Belt: Few cracks, wi th 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.

REINST ALL

1. W hile having an assistant hold the tens ioner in

the unloaded position (arrow) with a 15 mm

ring spanner, ins tall the engin e accessor y drive

belt, routing in the same manner as noted on

removal and as shown.

Figure 6B3-34

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 Screw-on Cap Test Adaptor 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 Adaptor 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 a pressure of 125 kPa and holds

pressure above 95 kPa. Should the cap fail to

reach or hold the specified pressures, install a

new pressure cap.

5. Prior to instal lin g s c r ew-on pres s ure c ap, c heck

that the coolant surge tank filler neck threads

and cap seating surface are clean and

undamaged.

Figure 6B3-35

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 remove screw-on pressure

cap while the engine coolant temperature is

above 50°

°°

° C, as personal injury will most likely

occur.

2. Carefully remove the screw-on pressure cap.

3. Connect the female half of Test Adaptor 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 cont aminatio n wi th 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 M ETHOD, in

this Section.

Figure 6B3-36

2.9 THERMOSTAT

LT SECTION NO. – 00-350

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 screw-on pressure

cap while the engine coolant temperature is

above 50°

°°

° C, as personal injury will most likely

occur.

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 type hose

clamps. Failure to do so could result in eye

injury.

Figure 6B3-37

4. Remove thermostat housing bolts (1), then

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

seal from the coolant pump.

Figure 6B3-38

TEST

1. Suspend thermostat and a suitable thermometer in a container of 50/50 extended life anti-freeze coolant

(conforming to GM6277M) and water.

NOTE: Neither the thermostat nor thermometer should rest on the bottom of the container because of uneven

concentration of heat at this point when the container is heated.

2. Heat container until thermostat begins to open.

Agitate solution to ensure uniform temperature.

Note tem per atur e a nd ensu r e thermos tat op ens

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. Install a new thermostat if it does not meet the

specified temperatures.

Thermostat Specifications

Opening Temperature 86° C

Fully Open Temperature 100° C

Figure 6B3-39

DISMANTLE

IMPORTANT: Only dismantle the thermostat if a

reverse flushing operation of the cylinder block is to

be carried out. If testing shows that r eplacement is

required, the thermostat and housing are only

serviced as a complete assembly.

1. Secur e the thermos tat housing by grip ping in a

vice fitted with soft jaws.

2. While compressing 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 6B3-40

3. Careful 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.

Figure 6B3-41

REASSEMBLE

Reassembly is the reverse of disassembly

procedures, except that the valve seat in the

therm ostat housing m ust be c hecked f or corros ion,

scratching or other damage and the valve seating

surface wiped with a clean rag.

REINST ALL

1. Shake the thermostat assembly 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. Install thermostat assembly, with a new O-ring

(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

TORQUE SPECIFICATION 14 Nm

5. Install radiator hose and clamp to thermostat

housing.

CAUTION: Always wear protective safety

glasses when working with spring type hose

clamps. Failure to 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 T EST ING in this Section.

Figure 6B3-42

2.10 COOLANT RECOVERY SURGE TANK

LT SECTION NO. – 01-140

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 screw-on pressure

cap while the engine coolant temperature is

above 50°

°°

° C, as personal injury will most likely

occur.

2. Drain the engine coolant into a suitable

container. Refer to 2.3 DRAINING AND

FILLING THE COOLING SYSTEM, in this

Section.

3. Disconnect radiator hose from surge tank inlet

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

(3).

CAUTION: Always wear protective safety

glasses when working with spring type hose

clamps. Failure to do so could result in eye

injury.

Figure 6B3-43

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 (arrow ‘B’) toward the engine

to remove from the anchor point attached to

the inner fender skirt.

Figure 6B3-44

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, cracks or distortion. Install a new surge tank

assem bl y as required.

REINST ALL

Reinstallation of the surge tank assembly is the reverse of removal procedures, noting the following points:

1. Refill cooling system, refer to 2.3 DRAINING A ND FILLING COOLING SYSTEM in this Section.

2. Check for cooling system leaks, refer to 2.8 PRES SUR E TESTING in this Section.

2.11 ENGINE COOLANT LEVEL SWITCH

REMOVE

1. Remove the recovery surge tank; refer

2.10 COOLANT RECOVERY SURGE TANK,

but leave the screw-on cap and all hoses still

connected.

NOTE: The coolant level switch does not contact

the coolant, so there should be no coolant loss

during this service procedure.

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

access to the engine coolant level switch (3),

as shown.

3. Disconnect the coolant level switch harness

connector (2), after releasing the locking tang.

Figure 6B3-45

4. 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.

5. Using the reco ver y surge tank (2) as a pl ace of

purchase, dislodge the coolant switch (1) from

the recovery surge tank by wiggling the switch

gently side to side while levering the switch in

an upward direction away from the tank.

NOTE: The switch is a very firm fit and will requ ire

a little force to dislodge it from the recovery surge

tank.

Figure 6B3-46

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 for free movement of the coolant level

float located in the recovery surge tank, by

shaking the tank and listening/observing float

movement.

3. Check the recovery surge tank assembly for

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

Install a new surge tank assembly as requir ed,

refer to 2.10 COOLANT RECOVERY SURGE

TANK, in this Section.

4. Check the operation of the coolant level

switch. For coolant level switch diagnostics

refer to COOLANT LEVEL SWITCH, in

Section 6C3-2C FUNCTION CHECKS – GEN

III V8 ENGINE.

Figure 6B3-47

REINST ALL

Reinstal lation of th e coolan t level switc h and surg e

tank assembly is the reverse of removal

procedures , not ing the fo llo wing points :

1. Apply a small amount of moisture to the

coolant level switch O-ring seal, prior to

reinstallation.

Figure 6B3-48

2. Using suitable hand protection (glove), install

the coolant level switch (1) by pushing it firmly

into the recovery surge tank (2), aperture.

CAUTION: As the force required to reinstall the

switch could cause injury from sharp edges on

the switch, hand protection is strongly

recommended.

3. Check the coolant level switch is completely

home in the surge tank aperture.

4. Reinstall the coolant recovery tank. Refer

2.10 COOLANT RECOVERY TANK, in this

Section.

5. Start the engine and check f or coolant leak age

from the recovery tank area.

Figure 6B3-49

2.12 OIL PAN UNDER-TR AY

REMOVE

1. Raise front of vehicle and support on safety

stands. Refer to Section 0A GENERAL

INFORMATION in the MY 2003 VY and V2

Series Service Information, for the location of

jacking and support points.

2. Remove the four bolts securing the under-tray

to the crossmember and remove tray from

vehicle.

REINST ALL

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. DO NOT OVER TIGHTEN.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 Nm

Figure 6B3-50

2.13 AIR BAFFLES

REPLACE

1. Raise front of ve hic l e a nd s uppor t on s af et y sta nds . R ef er to Section 0A GENERAL INFORMATION in the M Y

2003 VY and V2 Series Service Information, for the location of jacking and support points.

2. Remove the oil pan under-tray. Refer 2.12 OIL PAN UNDER-TRAY, in this Sec ti o n.

Standard GEN V8 Engine (View ‘A’)

3. Rem ove the lower air chute extension screws (4) (two places), lower the rear of the lower air chute extension

(3), slide the baffle rearward to disengage from the lower air chute (1), then remove from the vehicle.

4. Remove lo wer front baffle (1) to crossmember f asteners (2) (four places) and remove front air chute baffle (1)

from the vehicle.

SS Models, Including Utility (View ‘B’)

5. Remove the front bumper bar, refer to Section 1D BUMPER BARS.

NOTE: W hile the air duc t c an be rem oved without f irst rem oving t he bumper bar, ex cess ive distor tion of the duct is

required, both on removal and reinstallation. Also the reinstallation of the two upper scrivets is extremely difficult.

6. Remove the two scrivet fasteners (3) securing both the lower front baffle (2) and the duct (1) to the front

suspension crossmember, then remove the lower front baffle from the vehicle.

7. Rem ove the two scr ivet fas teners (4) securing t he air duct (1), t o the f ront upper panel as sembl y, the n remove

the duct from the vehicle.

8. Reinstallation is the reverse to removal procedures.

NOTE 1: Do not overtighten any of the fasteners.

NOTE 2: View ‘A’ in Figure 6B3-51 shows the standard GEN III lower baffle, while view ‘B’ shows the SS model

arrangement for all, including Utility.

Figure 6B3-51

2.14 COOLANT PUMP

LT SECTION NO. – 00-325

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 c ool to am bie nt temperatur e ( les s th a n 50 ° C), then slowly remove screw-on pressure cap from

the coolant surge tank.

CAUTION: Do not remove screw-on pressu re cap w hile the engine coolant temperature is above 50 °

°°

° C, as

personal injury will most likely occur.

2. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES befor e disc onn ec tin g the battery.

3. Remove engine dress cover decorative nuts

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

4. Lift the locking lever on the Intake Air

Temperature (IAT) sensor wiring harness

connector (3), then remove the connector.

5. Loosen the two intake duct clamps, then

remove the duct (4).

Figure 6B3-52

6. Rem ove engine accessory drive belt (2), using

a 15 mm ring spanner to move the belt

tensioner (1) in th e direc tio n ind icated. Ref er t o

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 type hose

clamps. Failure to do so could result in eye

injury.

Figure 6B3-54

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

belt tensioner (2) to the coolant pump housing

and set the tensioner to one side.

Figure 6B3-55

10. Loosen, then remove the six bolts (1) securing

the coolant pump (2) to the cylinder block.

11. If neces s ar y, use a sof t f ac ed ham mer to lig htly

tap coolant pump housing (2) to dislodge it

from the cylinder block.

12. Remove coolant pump gaskets (3) and discard.

Figure 6B3-56

DISMANTLE

NOTE: Apart f rom the s er vice oper ations des c ribe d

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 pump (2). Tap

with a sof t faced h amm er to dislodge the cover

from the pump body.

2. Remove the seali ng O-ring (1) f rom the coolant

pump body (2).

3. For thermostat remove, test and reinstall

procedures, refer to 2.9 THERMOSTAT in this

Section.

Figure 6B3-57

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 surfaces for scratches, 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.

• Evidenc e of c oolant leak age at th e cool ant out let hous ing or rear c over gas k et (if these p arts hav e not be en

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 14 Nm

REINST ALL

Reinstallation is the reverse to removal except 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 reinstall the coolant pump to the

cylinder bl oc k.

3. Reinstall remaining bolts and tighten to the correct torque specification, in two stages.

COOLANT PUMP BOLT

TORQUE SPECIFICATION Stage 1: 15 Nm

Stage 2: 25 Nm

4. Reinstall the engine accessory drive belt tensioner and attaching bolts, tightening to the correct torque

specification.

ENGINE ACCESSORY DRIVE

BELT TENSIONER BOLT

TORQUE SPECIFICATION 50 Nm

5. Reinstall 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.

6. Reinstall the engine accessory drive belt. Refer 2.7 ENGINE ACCESSORY DRIVE BELT, in this Section.

7. Refill cooling system, refer to 2.3 DRAINING A ND FILLING COOLING SYSTEM in this Section.

8. Check for cooling system leaks, refer to 2.8 PRES SUR E TESTING in this Section.

2.15 COOLING FANS & SHROUD ASSEMBLY

LT SECTION NO. – 01-105

REMOVE

1. Allow engine to cool to ambient 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 screw-on pressu re cap w hile the engine coolant temperature is above 50 °

°°

° C, as

personal injury will most likely occur.

2. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES befor e disc onn ec tin g the battery.

3. Remove engine dress cover decorative nuts

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

4. Lift the locking lever on the Intake Air

Temperature (IAT) sensor wiring harness

connector (3), then remove the connector.

5. Lift the locking lever on the Mass Air Flow

(MAF) sensor, then remove the connector.

6. Loosen the two intake duct clamps, one at the

throttle body and the other at the MAF to air

cleaner c onnect ion. Rem ove the duct a nd MAF

as an assembly and carefully set to one side.

7. Drain engine coolant into a suitable, clean

container. Refer to 2.3 DRAINING AND

FILLING COOLING SYSTEM, in this Section.

8. Release the vapour hose from the radiator fan

shroud clips, remove the clamp securing the

hose to the radiator, remove the hose and

route to one side.

9. Remove the clamp securing the vapour hose to

surge tank at the radiator end. Remove the

hose and route to one side.

Figure 6B3-58

10. Remove the 4 radiator upper shroud retainers

(2) by carefully lifting the inner stud with a

sm all screwdriver . Lift the upper shroud (1), on

the right side first, to allow release of the

locating tab on the lef t han d end.

Figure 6B3-59

11. Remove the upper rad iator hos e clam ps (worm

drive at coolant pump and spring type at

radiator), then remove the hose (1) and set to

one side.

CAUTION: Wear eye protection when working

with spring type hose clamps.

Figure 6B3-60

12. Press the retaining tang on wiring harness to

cooling f an m otor wirin g ha rness connector (1),

then separate the connector halves.

Figure 6B3-61

13. While holding the shroud locking tang in the

release position, lift the shroud and fan

assembly upwards. Repeat for the second

side.

NOTE: While the automatic transmission fluid

cooling pipe is shown removed, this is not a

mandatory requirement for shroud removal. Pipe

has been s ho wn rem oved t o m ore c learly sho w the

shroud release method.

Figure 6B3-62

14. Lift the shr oud and f an assem bl y clear from the

engine bay, grasping the motor mounting

brackets.

IMPORTANT: Do not lift the assembly clear by

lifting on the fan rings as this will bend the fan

motor shaft and create an unnecessary vibration.

Figure 6B3-63

DISASSEMBLE

IMPORTANT: E ither f an is are n ot to be s eparated

from its fan motor. The assembly is carefully

balanced during manufacture and duplication of

this balance is not possible, on reassembly.

1. Separate the intermediate wiring harness

connector (5) and remove motor assembly

wiring harness (1) from the integral clips that

form a part of the shroud (3).

2. Remove screws (4) attaching the motor and

fan assemblies (2) to the shroud (3), then

remove the motor, fan and wiring (2) from the

shroud.

3. Repeat for the second fan, motor and wiring

harness, as required.

Figure 6B3-64

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 SPECIFICATION 5.0 Nm

2. Ensure that all wiring is routed correctly and secured by the shroud clips.

REINST ALL

Reinstallation of the cooling fan and shroud assembly is the reverse of removal procedures, noting the following

points:

1. Ensure that fan and shroud assem bly to radiator attaching clips are all fully engaged and that the two locking

tangs on the upper clips secure the shroud correctly.

2. Refill cooling system and test concentration levels. Refer 2.3 DRAINING AND FILLING COOLING SYSTEM

and TESTING COOLANT CONCENTRATION, in 2.2 COOLANT MAINTENANCE, both in this Section.

3. Check cooling fan operation, refer to Section 6C3 POWERTRAIN MANAGEMENT - GEN III V8 ENGINE in

the MY 2003 VY and V2 Series Service Information. Also check for the correct cooling fan rotation direction.

2.16 RADIATOR

LT SECTION NO. – 01-105

REMOVE

1. Allow engine to cool to ambient 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 screw-on pressu re cap w hile the engine coolant temperature is above 50 °

°°

° C, as

personal injury will most likely occur.

2. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to Section 00

CAUTIONS, 5. Battery Disconnection Procedures before disconnecting the battery.

3. Remove engine dress cover decorative nuts

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

4. Lift the locking lever on the Intake Air

Temperature (IAT) sensor wiring harness

connector (3), then remove the connector.

5. Lift the locking lever on the Mass Air Flow

(MAF) sensor, then remove the connector.

6. Loosen the two intake duct clamps, one at the

throttle body and the other at the MAF to air

cleaner c onnectio n. Rem ove the duct and MAF

as an assembly.

Figure 6B3-65

7. Loosen radiator lower hose worm drive clamp

from radiator connection (1).

8. Remove the h os e and dr a i n en gi ne co ol ant in to

a suitable, clean container. Refer to

2.3 DRAINING AND FILLING COOLING

SYSTEM, in this Section.

9. Remove radiator upper hose from radiator (2),

after releasing the spring type hose clamp,

using suitable pliers.

CAUTION: Always wear protective safety

glasses when working with spring type hose

clamps. Failure to do so could result in eye

injury.

10. Remove the fan and shroud assembly, refer

2.15 COOLING FAN AND SHROUD

ASSEMBLY, in this Section.

NOTE: The fan and shroud assembly must be

removed separately, to provide the required space.

Figure 6B3-66

Techline

11. Remove the 4 radiator upper shroud retainers

(2) b y caref ul ly lifting the in ner s t ud with a small

screwdriver. Lift the upper shroud (1), on the

right side first, to allow release of the locating

tab on the left hand end.

12. Releas e t he c li p sec ur ing the ref riger a nt pi pe to

the receiver drier at the left side of the radiator.

Figure 6B3-67

NOTE: If fitted with air conditioning, the condenser

must be separated from the radiator assembly. This

action wil l allo w the radiat or r emoval with out hav ing

to open any refrigerant lines.

13. Remove the three grille securing screws (1).

Tilt the grille (2) forward at the top, then lift to

free the three locating pins (3). Carefully set to

one side.

NOTE: The grille on ‘S’ sedan and ‘SS’ model

vehicles is secured in a sim ilar m anner but has two

lugs on the lower edge rather than the three pins

(3) shown here.

Figure 6B3-68

14. Working thr ough t he gr ill e o pen ing, r e le as e on e

of the clips securing the condenser to the

radiator. Do this by pressing down on the lug

with the fingers of one hand, while lifting the

condenser assembly with the other. Repeat for

the other side.

NOTE: It is not necessary to remove the receiver

drier, nor disturb the air conditioning refrigerant

system (where fitted), for this operation. The

condenser can be lifted against the spring of the

attached refrigerant pipes.

15. Once released, pull the condenser assembly

forward to clear the radiator mounting lugs.

Figure 6B3-69

16. If the vehicle is fitted with an automatic

transmission, disconnect the transmission oil

cooler line quick connect fittings, using Tool

No. AU525, as described:

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, to

release, then pull back on the pipe.

NOTE: If Tool No. AU525 is not available, the

cooler pipes can be disconnected from the cooler,

in the left side radiator tank, by removing the quick

connect fitting, using conventional tools. Do not

lose the sealing washer.

c. Plug al l openings to minim ise f luid loss and

prevent dirt entry.

Figure 6B3-70

17. Using a screwdriver, compress and lever out

radiator retaining clip (1) from radiator upper

mounting bracket, on each side.

18. Lift radiator upwards out of lower ins ulators. T o

rem ove the radiator as sembly fr om the vehicl e,

after clearing the top insulators, move the

radiator rearward on the left side, then across

to the left, to allow the right side to clear the

mounting brackets.

Remove upper insulators (2) from radiator

upper mounting pins.

Figure 6B3-71

REINST ALL

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 compressed air, working from

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 checking that the

clips engage on both sides of the channel

support bracket.

4. Reins tall th e lower ra diator hose, secur ing with

the worm drive hose clamp.

5. If the vehicle is fitted with an automatic

transmission, remove plugs from the removed

cooling pipe ends and the two quick connect

fittings.

6. After wiping cooling pipe ends and smearing

clean automatic transmission fluid over each

flared pipe end, push into the quick connect

fitting to engage. As a security check, tug on

each pipe to ensure correct engagement.

NOTE: If the quick connect fittings were removed

from the left hand radiator tank , inspect t he sealin g

washer for serviceability before reinstallation.

Replace the sealing washer/s as required. Tighten

the quick connect fittings to the correct torque

specification.

QUICK CONNECT FITTINGS TO

TRANSMISSION FLUID COOLER

TORQUE SPECIFICATION 25 Nm

Figure 6B3-72

7. After reinstalling the condenser assembly to

the four retaining clips, ensure that the two

lower clips have fully engaged.

8. Reinstall the grille and the three retaining

screws. Do not over- tig hten .

9. Secure the air conditioning compressor

discharge pipe b y clos ing the plas tic clip at the

top left of the radiator, engaging the locking

tang.

10. Reinstall the upper radiator shroud (1), by first

engaging the lug on the left side, before

reinstalling the four retainers (2).

11. Reinstall the following hoses;

a. Vapour h ose to the r ad iat or f itting , s ec uri ng

with the spring clamp. Secure the vapour

hose with the integral clips on the radiator

fan shroud.

b. The surge tank hose to the radiator and

secure with the spring clamp.

c. Upper radiator hose, securing with the two

securing hose cl amps.

12. Refill cooling system, refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM in this

Section.

13. Check for coolant leaks, refer to

2.8 PRESSURE T EST ING in this Section.

14. Check cooling fan operation, refer to

Section 6C3 POWERTRAIN MANAGEMENT

– GEN III V8 ENGINE in the MY 2003 VY and

V2 Series Service Information.

Figure 6B3-73

RADIATOR REPAIR PROCEDURE

Repairable Leaks

There are two types of leaks that can be repaired

on the aluminium-plastic radiator; core leaks and

automatic transmission oil cooler seal leaks. Leaks

in the plastic tanks or the seals between the side

tanks and the headers cannot be repaired,

requiring the radiator to 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 fittings and the tank (vehicles with automatic

transmission).

While some leaks may be repaired while the

radiator remains installed, it is strongly

recommended that the radiator is removed from

the vehicle before attempting any repairs.

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 replacement is necessary if damage

is any greater.

Figure 6B3-74

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 current release of PartFinder® for the

Aluminis e d Sil icon bas e li q uid par t 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 6B3-75

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

possibl y result in an overheated eng ine.

The tube should be cut off 6 mm from the header

(1) and pinched shut before it is cleaned and

sealed, refer to GENERAL CORE REPAIR, later in

this Section.

Figure 6B3-76

Header Repair

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

the removal of the header tank, then the radiator must be replaced.

General Core Repair

IMPORTANT: T he need f or caref ul preparati on of the surfac e in the repa ir area c annot be over-em phasised. If the

leak area surface is not clean, the repair material will not adhere to the surface.

1. Dr ain the c ooling s ystem . Refer to 2.3 D R AINING AND FILLING COOLING SYSTEM in this Section. Remove

the radiator, refer 2.16 RADIATOR, REMOVE, 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 cases of extended shelf life, the silicon in solution may separate

from the thinner carrier. Should this occur, mix contents well until agent is homogeneous again.

6. Apply repair agent sparingly to damaged area. Do not apply an excessive amount, as this will cause a

blockage of the radiator tube.

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

7. Allow radiat or to s tand in a c lean, dry area for a m inim um of three hour s (at am bient temper ature of 20 – 30° C)

with adequate ventilat ion .

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 L eak Test

If the transmission oil cooler is suspected of leaking transmission fluid, test it before replacing the radiator, as

follows:

1. Disconnect oil cooler pipes from the flexible hose connections, using release tool AU525.

2. Using suitable connections, plug one of the flexible hoses and connect an air supply to the other.

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 Replacem ent .

It is strongly recommended that the quick connect fittings at the left radiator header tank, not be disturbed. If

coolant is found to leak from ether of these two areas then the radiator should be replaced.

3. ENGINE COOLING SYSTEM DIAGNOSIS

3.1 ENGINE OVERHEATING

DEFINITION: En gine tem perature lamp com es O N and sta ys ON, or the tem peratur e gauge sh ows 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 coolant.

2. Refer 2.2 COOLANT MAINTENANCE, Topping Up Cooling

System, in this Section.

Is there a loss of coolant?

—

Refer 3.2 LOSS

OF COOLANT,

in this Section.

Go to Step 2

2 1. Check for weak engine coolant solution.

2. Refer 2.2 COOLANT MAINTENANCE, Testing Coolant

Concentration, in this Section.

Does the engine still overheat ?

—

Go to Step 3

System OK

3 1. Check for obstruct ed radi ator air flow or bent radiator f i ns.

2. If necessary, remove or rel ocate added-on parts that block air

to the radiator. Clean away any ins ects, leaves, or other

debris.

Does the engine still overheat ?

—

Go to Step 4

System OK

4 1. Check for a loss of system pressure.

2. Conduct a test on the pressure c ap. Ref er 2.8 PRESSURE

TESTING, Screw-On Pressure Cap Testing, in this Section.

Does the engine still overheat ?

—

Go to Step 5

System OK

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

Refer 6C3 POWERTRAIN MANAGEMENT - GEN III V8

ENGINE.

2. Replace sensor as necessary.

Does the engine still overheat ?

—

Go to Step 6

System OK

6 1. Check for a damaged coolant surge tank.

2. Check for a leaking or kinked surge tank hos e.

3. If necessary, replace the surge tank hose and/or replace the

coolant surge tank. Refer 2.10 COOLANT SURGE TANK, in

this Section.

Does the engine still overheat ?

—

Go to Step 7

System OK

7 1. Check the tensi on of the engine accessory drive belt . Ref er to

2.6 ENGINE A CCESSORY DRIVE BELT TENSION, in this

Section.

2. Replace the engine accessory drive belt as necessary. Refer

to 2.7 ENGI NE ACCESSO RY 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. Reverse flush the cooling system. Refer to 2.5 CLEANING

THE COOLING SYSTEM, in this Section.

Does the engine still overheat ?

—

Go to Step 9

System OK

9 1. Check for incorrect or dam aged cooling f an blade(s ).

2. Check for the correct fan blade(s) part number.

3. Replace fan/s as nec essary. 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 MANAGEMENT - GEN III V8 ENGINE.

2. Replace cooling fan/s and/or motor, as necessary. Refer 2.14

COOL IN G F AN S AND SH R O U D ASSEMBLY, in this Se ction.

Does the engine still overheat ?

—

Go to Step 11

System OK

11 1. Check for correct thermostat operation. Refer 2.9

THE RMOSTAT, Test, in this Section.

2. Replace thermostat assembly as necessary. Refer

2.9THERMOSTAT, in this Secti on.

Does the engine still overheat ?

—

Go to Step 12

System OK

12 1. Check for correct coolant pump operation.

2. Replace coolant pump assembly as necess ary. Refer 2.13

COOLANT PU M P, in this Se ct ion .

Does the engine still overheat ?

—

Go to Step 13

System OK

13 1. Check the radiator cooling capacity.

Is the radiator the correct part f or the GEN III V8 engine? —

System OK

Go to Step 14

14 1. Replace the radiator with the correct part.

Is the repair 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 incorrect or faulty screw-on pressure cap.

Conduct a test on the pressure c ap. Ref er 2.8 PRESSURE

TESTING, Screw-On Pressure Cap Testing, in this Section.

2. Replace the screw-on press ure cap as necessary.

Is a coolant loss still evident?

—

Go to Step 2

System OK

2 1. Check for a leaking or damaged coolant s urge 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. Conduct a pressure test of the cooling s yst em. Refer 2. 8

PRESSURE TESTING, Cooling System Pressure Testing, in

this Section.

Does test indicat e a pressure loss in the cooli ng system ?

—

Go to Step 4

System OK

4. Is there evidence of an external coolant leak? — Go to Step 5 Go to Step 12

5. 1. Check for loose or damaged surge tank, radiator and heater

hoses. Refe r 2.4 COOLANT HOSES, in this Section.

2. Replace hose/s as necessary.

Is a coolant loss still evident?

—

Go to Step 6

System OK

6. 1. Check for a coolant leak from the coolant pump gaskets.

2. Replace gaskets as necessary. Refer 2.13 COOLANT PUMP,

in this Section.

Is a coolant loss still evident?

—

Go to Step 7

System OK

7. 1. Check for a coolant leak from the coolant pump, rear O-ring

seal and thermostat housing O-ring seal.

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

and 2.13 COOLANT PUMP, in this Section.

Is a coolant loss still evident?

—

Go to Step 8

System OK

8. 1. Check for a coolant leak from the coolant pump, shaft seal.

2. Replace coolant pump as necessary. Ref er 2. 13 COOLANT

PUMP, in this Section.

Is a coolant loss still evident?

—

Go to Step 9

System OK

9. 1. Inspect the radiator for coolant l eaks.

Are coolant leaks from the radiator evident? —

Go to Step 10

System OK

10. 1. If radiator leaks are mi nor, repai r as det ailed in 2.15

RADIATOR, Radi ator Repai r Procedure, in this Section.

2. If radiator coolant leaks are major, replace the radiator. Refer

2.15 RADIATOR, in this Secti on.

Is a coolant loss still evident?

—

Go to Step 11

System OK

11. 1. Check for coolant leaks from the heater core.

2. Replace heater core as necessary. Ref er 2B AIR

CONDITIO NING - REMOVAL & INSTALLATION.

Is a coolant loss still evident?

—

Go to Step 12

System OK

12. 1. Check for coolant leaks from the following;

• Engine block plugs.

• Vapour pipe and/or fitti ngs

• Cylinder head gask et/s .

2. Make the necessary repairs or replace aff ected components.

Refer 6A3 ENGINE MECHANICAL – GEN III V8 ENGINE.

Is/are the repair/ s complete?

—

System OK

—

3.3 ENGINE FAILS TO RE ACH NORMAL OPE RATING TEMPERATURE

Step Action Value Yes No

1 1. Check for correct coolant level in the coolant surge tank.

When checked cold, the level should be at the FULL COLD

mark.

Is the coolant level correc t?

—

Go to Step 3

Go to Step 2

2 1. Top up with correct mixture of extended life anti-freeze

coolant (conforming to GM6277M) and clean, good

quality water. Refer 2.2 COOLANT MAINTENANCE, in this

Section.

Does the engine reach normal operating t em perature now?

—

System OK

Go to Step 3

3 1. Check for a blockage in the cooling system passages.

2. Reverse flush the cooling system. Refer 2.5 CLEANING

COOLIN G SYSTEM, in this Sectio n .

Does the engine reach normal operating t em perature now?

—

System OK

Go to Step

4 1. Check that the correct thermostat is fitted.

2. Check that the thermostat is not stuck in the open position.

3. Replac e the thermostat as necessary. Refer 2.9

THERMOSTAT, in this Section.

Are repairs complete?

—

System OK

—

3.4 BLACK LIGHT AND DYE LEAK DIAGNOSIS METHOD

It is strongly recommended that the black light and dye method is used to diagnose and locate 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 s uitable f or various t ypes of leak dete ction, when us ed with th e appropriat e tracer d ye and can be

used for detecting engine coolant, engine oil, transmission 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 a dark, muddy green. As the use of extended life anti-freeze coolant (conforming

to GM 6277M ) to this cooling system is mandat ory and is not t o be mixed with ot her composition coolant s,

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 extended life anti-freeze coolant (conforming to GM6277M) 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. Direc t the black light towar ds the suspec t area. An y fluid leak will appear as a brightl y 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

GENERAL

Radiator Cap Pressure Rating

Nominal.............................................................. 103 kPa

Range................................................................. 96.5 – 124 kPa

Cooling System Capacity........................................ 14.3 Litres

Coolant Corrosion Inhibitor ..................................... Extended life anti-freeze coolant, conforming to

GM6277M, approx. 7 litres required when changing

coolant.

THERMOSTA T

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

Starts to open at...................................................... 86° C

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

COOLANT PUMP

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

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

Bear ing T ype........................................................... Double-ro w ball bear i ng

RADI ATOR

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

Overall Width........................................................... 826 mm

Overall Height ......................................................... 495 mm

Core Width.............................................................. 674 mm

Core Height............................................................. 427 mm

Core Thickness....................................................... 35 mm

Plastic tanks............................................................ Nylon 6,6 (30% Glass Filled)

RADIATOR HOSES

Lower – Number and type....................................... Two, Moulded

Upper – Number and type....................................... One, Moulded

SMALL ENGINE COOLING FAN (Left)

Fan – Design.............................................................. Asy mmetrical spaced, curved blades with outer ring

Material.................................................................... Nylon 6,6 (30% Glass Filled), with zinc coated metal

hub insert

Number of Blades ................................................... 5

Diameter.................................................................. 293 mm

Fan Motor – Type ...................................................... Dual speed, 4 brush with 4 permanent magnets

Housing................................................................... Semi-sealed, zinc coated steel with drain hole

Direction of Rotation................................................ Counter-clockwise (as viewed from motor side)

Power...................................................................... 180 Watts (nominal)

Rotational Speed (with 12 volts applied, Radiator

and Condenser Installed – Stage 1................... 2,050 ± 150 rpm

– Stage 2................... 2,300 ± 150 rpm

LARGE ENGINE COOLING FAN – (Right)

Fan – Design.............................................................. Asy mmetrical spaced, curved blades with outer ring

Material.................................................................... Nylon 6,6 (30% Glass Filled), with zinc coated metal

hub insert

Number of Blades ................................................... 5

Diameter.................................................................. 342 mm

Fan Motor – Type ...................................................... Dual speed, 4 brush with 4 permanent magnets

Housing................................................................... Semi-sealed, zinc coated steel with drain hole

Direction of Rotation................................................ Counter-clockwise (as viewed from motor side)

Power...................................................................... 220 Watts (nominal)

Rotational Speed (with 12 volts applied, Radiator

and Condenser Installed – Stage 1................... 2,350 ± 150 rpm

– Stage 2................... 2,750 ± 150 rpm

5. TORQUE WRENCH SPECIFIC ATIONS

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

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

Coolant Pump Rear Cover Bolts........................................... 14

Engine Accessory Drive Belt Tensioner Bolt........................ 50

Fan Motor to Shroud Screw.................................................. 5.0

Oil Cooler to Side Tank Nuts................................................ 25

Oil Pan Under-T ra y Bolts...................................................... 30

Quick Connect Fitting to Transmission Fluid Cooler ............ 25

Thermostat Housing to Coolant Pump Bolts ........................ 14

6. SPECIAL TOOLS

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

AU505

COOLING SYSTEM

HYDROMETER

Also released as AU435

Also commercially available

Mandatory

AU525

QUICK CONNECT RELEASE

TOOL

Use to release the quick connect

fittings on the automatic

transmission fluid cooler lines at

the radiator end, when the veh ic le

is so equipped.

Previously released.

Mandatory

J 24460-92

COOLING SYSTEM TEST

ADAPTORS

Used to pressure test the screw-

on cooling system pressure cap

and the cooling system.

Previously released.

Mandatory

J 26568 REFRACTOMETER

Previously released, also under

the number, AU435.

Mandatory

N/A

COOLING SYSTEM PRESSURE

TESTER

Used in conjunction with adaptors

J 24460-92

Commercially available.

Available