Beruflich Dokumente
Kultur Dokumente
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . .
14-2
14-24
SERVICE SPECIFICATIONS. . . . . . .
14-2
14-25
LUBRICANT. . . . . . . . . . . . . . . . . . . .
14-2
THERMOSTAT . . . . . . . . . . . . . . . . . .
14-26
14-26
SEALANTS . . . . . . . . . . . . . . . . . . . .
14-2
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
14-27
SPECIAL TOOLS. . . . . . . . . . . . . . . .
14-3
WATER PUMP . . . . . . . . . . . . . . . . . .
14-28
14-28
14-29
TROUBLESHOOTING . . . . . . . . . . . .
14-4
ON-VEHICLE SERVICE. . . . . . . . . . .
14-22
14-30
14-22
14-30
14-32
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
14-33
RADIATOR . . . . . . . . . . . . . . . . . . . . .
14-34
14-34
14-22
14-22
CONCENTRATION MEASUREMENT . . . .
14-23
14-23
ENGINE COOLING
14-2
GENERAL INFORMATION
GENERAL INFORMATION
M1141000100371
Item
Radiator
Specification
Performance kJ/h
4G13
4G18
Standard vehicles
137,720
161,288
Standard vehicles
161,288
181,800
4G63
A/T oil cooler
181,800
Performance kJ/h
5,651
SERVICE SPECIFICATIONS
M1141000300416
Item
Standard value
Limit
93 123
Minimum 83
30 60
Thermostat
4G1
88 1.5
4G6
82 1.5
Full-opening temperature of
thermostat C
4G1
100
4G6
95
8.5 or more
Valve lift mm
LUBRICANT
M1141000400338
Item
Specified coolant
Quantity L
5.0
7.0
SEALANTS
M1141000500324
Item
Specified sealant
ENGINE COOLING
14-3
SPECIAL TOOLS
SPECIAL TOOLS
M1141000600246
Tool
Number
Name
Use
MB991502
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826
B991502
MB991824
MB991827
DO NOT USED
MB991910
MB991911
MB991825
MB991826
MB991955
ENGINE COOLING
14-4
TROUBLESHOOTING
Tool
A
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
MB991871
LLC changer
Coolant refilling
D
MB991223 AC
MB991871
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600360
Trouble symptom
Inspection
procedure No.
Reference page
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with
A/C)> or A/C condenser fan <4G6> do not operate
P.14-5
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with
A/C)> or A/C condenser fan <4G6> do not change speed or stop
P.14-16
Cooling fan (L.H.) does not operate {When cooling fan (R.H.)
3
<4G1> or A/C condenser fan <4G6> operate} <Vehicles with A/C>
P.14-20
Cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> does not
operate {When cooling fan (L.H.) operate} <Vehicles with A/C>
P.14-21
ENGINE COOLING
14-5
TROUBLESHOOTING
INSPECTION PROCEDURE 1: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or
A/C Condenser Fan <4G6> do not Operate
ENGINE-ECU <M/T> OR
ENGINE-A/T-ECU <A/T>
ENGINE CONTROL
RELAY
B-16X
21 C-123 <M/T>
18 C-122 <A/T>
1 A-13 <LHD>
12 C-111 <RHD>
1 2 3
4 5
6 7 8 9 10 11 12
FAN CONTROL
RELAY
A-09X
A-18
COOLING FAN
MOTOR DRIVE
CONTROL UNIT
COOLING FAN
MOTOR (R.H.)
<4G1 (VEHICLES
WITH A/C>
OR
A/C CONDENSER
FAN MOTOR <4G6>
A-18-1
A-18-2
COOLING FAN
MOTOR (L.H.)
CIRCUIT OPERATION
The cooling fan motor drive control unit is
powered from fusible link (2).
AC303577
14-6
ENGINE COOLING
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Check the cooling fan motor (L.H.).
<Vehicles without A/C>
Refer to P.14-25.
Q: Is the cooling fan motor (L.H.) in good condition?
YES : Go to Step 2 .
NO : Replace the cooling fan motor (L.H.) (Refer
A-18
3 2 1
AC100293 AD
AC000246AF
ENGINE COOLING
14-7
TROUBLESHOOTING
Connector: A-18
A-18
3 2 1
AC303511AB
AC100293 AD
Step 24 .
STEP 4. Check the fusible link No.2.
Relay box
Connector: A-09X
Fusible link
No.2
AC303509 AB
A-09X
Step 24 .
AC303510 AB
Connector: A-09X
A-09X
AC303510 AB
ENGINE COOLING
14-8
TROUBLESHOOTING
Connector: A-09X
Relay box
A-09X
Fusible link
No.2
AC303510 AB
AC303509 AB
Relay box
Connector: A-09X
A-09X
AC303510 AB
Relay box
Connector: A-09X
A-09X
AC303510 AB
Connector: A-18
Step 24 .
A-18
3 2 1
AC100293 AD
to Step 24 .
ENGINE COOLING
14-9
TROUBLESHOOTING
Connector: A-09X
A-09X
AC303517AB
AC303510 AB
ENGINE COOLING
14-10
TROUBLESHOOTING
Relay box
Connector: A-09X
C-12
C-12
Step 24 .
AC303524 AB
C-134
C-134
AC303525 AB
A-13
A-13
AC303526 AB
C-111
C-111
1 2 3
4 5
6 7 8 9 10 11 12
AC303527 AB
ENGINE COOLING
14-11
TROUBLESHOOTING
Connector: A-09X
C-12
A-09X
C-12
AC303510 AB
AC303524 AB
C-134
C-134
AC303525 AB
AC303533 AB
Relay box
Connector: A-09X
A-09X
AC303510 AB
ENGINE COOLING
14-12
TROUBLESHOOTING
Connector: A-09X
A-09X
A-18
3 2 1
AC303510 AB
AC100293 AD
A-18 Connector
(Wiring harness side)
Relay box
Connector: A-09X
A-09X
AC303510 AB
ENGINE COOLING
14-13
TROUBLESHOOTING
A-18
3 2 1
A-18
3 2 1
AC100293 AD
Step 24 .
AC100293 AD
ENGINE COOLING
14-14
TROUBLESHOOTING
Connector: A-18
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
A-18
3 2 1
AC100293 AD
C-122 <A/T>
AC303555 AB
A-13
A-13
Step 24 .
AC303526 AB
C-111
C-111
1 2 3
4 5
6 7 8 9 10 11 12
AC303527 AB
ENGINE COOLING
14-15
TROUBLESHOOTING
Connector: A-18
C-123 <M/T>
or
C-122 <A/T>
A-18
3 2 1
AC100293 AD
C-123 <M/T>
AC303555 AB
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
C-122 <A/T>
AC303559 AB
AC303555 AB
to Step 24 .
14-16
ENGINE COOLING
TROUBLESHOOTING
INSPECTION PROCEDURE 2: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or
A/C Condenser Fan <4G6> do not Change Speed or Stop
COOLING FAN (L.H.) AND COOLING FAN (R.H.)
OR A/C CONDENSER FAN DRIVE CIRCUIT
Refer to P.14-5.
CIRCUIT OPERATION
Refer to P.14-5.
TECHNICAL DESCRIPTION
If the communication line wiring harness between
the cooling fan motor drive control unit and the
engine-ECU <M/T> or the engine-A/T-ECU
<A/T> is open, the cooling fan motor (L.H.) and
the cooling fan motor (R.H.) <4G1 (Vehicles with
A/C)>, or the A/C condenser fan motor <4G6>
rotate to prevent the engine from overheating.
If the system voltage is continuously supplied to
the cooling fan motor drive control unit by a fan
motor relay malfunction and a short circuit on the
cooling fan motor drive control unit power supply
wiring harness, the cooling fan motor (L.H.) and
the cooling fan motor (R.H.) <4G1 (Vehicles with
A/C)>, or the A/C condenser fan motor <4G6>
rotate.
The cause could also be a malfunction of the
cooling fan motor (L.H.). <Vehicles without A/C>
DIAGNOSIS
STEP 1. Check the fan control relay.
Refer to P.14-24.
Q: Is the fan control relay in good condition?
YES : Go to Step 2 .
NO : Replace the fan control relay. Then go to
Step 8 .
ENGINE COOLING
14-17
TROUBLESHOOTING
Connector: A-09X
Connector: A-09X
Fan control relay
AC303510 AB
AC303510 AB
Connector: A-18
A-18
3 2 1
AC100293 AD
to Step 8 .
ENGINE COOLING
14-18
TROUBLESHOOTING
Connector: A-18
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
A-18
3 2 1
AC100293 AD
C-122 <A/T>
AC303555 AB
A-13
A-13
Step 8 .
AC303526 AB
C-111
C-111
1 2 3
4 5
6 7 8 9 10 11 12
AC303527 AB
ENGINE COOLING
14-19
TROUBLESHOOTING
Connector: A-18
C-123 <M/T>
or
C-122 <A/T>
A-18
3 2 1
AC100293 AD
C-123 <M/T>
AC303555 AB
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
C-122 <A/T>
AC303559 AB
AC303555 AB
to Step 8 .
14-20
ENGINE COOLING
TROUBLESHOOTING
INSPECTION PROCEDURE 3: Cooling Fan (L.H.) does not Operate {When Cooling Fan (R.H.) <4G1> or
A/C Condenser Fan <4G6> Operate} <Vehicles with A/C>
COOLING FAN (L.H.) AND COOLING FAN (R.H.)
OR A/C CONDENSER FAN DRIVE CIRCUIT
Refer to P.14-5.
CIRCUIT OPERATION
Refer to P.14-5.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the cooling fan
motor (L.H.) or cooling fan motor drive control unit.
TROUBLESHOOTING HINTS
Malfunction of cooling fan motor (L.H.)
Malfunction of cooling fan motor drive control unit
DIAGNOSIS
STEP 1. Check the cooling fan motor (L.H.).
Refer to P.14-25.
Q: Is the cooling fan motor (L.H.) in good condition?
YES : Go to Step 2 .
NO : Replace the cooling fan motor (L.H.) (Refer
ENGINE COOLING
TROUBLESHOOTING
14-21
INSPECTION PROCEDURE 4: Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> does not
Operate {When Cooling Fan (L.H.) Operate} <Vehicles with A/C>
COOLING FAN (L.H.) AND COOLING FAN (R.H.)
OR A/C CONDENSER FAN DRIVE CIRCUIT
Refer to P.14-5.
CIRCUIT OPERATION
Refer to P.14-5.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the cooling fan
motor (R.H.) <4G1> or A/C condenser fan motor
<4G6> or cooling fan motor drive control unit.
TROUBLESHOOTING HINTS
Malfunction of cooling fan motor (R.H.) <4G1> or
A/C condenser fan motor <4G6>
Malfunction of cooling fan motor drive control unit
DIAGNOSIS
STEP 1. Check the cooling fan motor (R.H.)
<4G1> or A/C condenser fan motor <4G6>.
Cooling fan motor (R.H.) check. (Refer to P.14-25)
<4G1>.
A/C condenser fan motor check. (Refer to GROUP
55 P.55-97) <4G6>.
Q: Is the cooling fan motor (R.H.) <4G1> or A/C
condenser fan motor <4G6> in good condition?
YES : Go to Step 2 .
NO : Replace the cooling fan motor (R.H.) (Refer
ENGINE COOLING
14-22
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
M1141001000300
! WARNING
When pressure testing the cooling system,
slowly release cooling system pressure to
avoid getting burned by hot coolant.
! CAUTION
Cap adapter
Adapter
! WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the cap and turn the
cap counterclockwise a little to let the
pressure escape through the vinyl tube.
After relieving the steam pressure, remove
the cap by slowly turning it
counterclockwise.
ACX01844 AC
Cylinder block
drain plug
AC208283 AC
<4G6>
Inlet side
M1141001300389
Cap adapter
Cylinder block
drain plug
AC303355 AB
AC211643 AB
ENGINE COOLING
ON-VEHICLE SERVICE
Cylinder block
drain plug
AC200625 AC
CAUTION
14-23
CAUTION
CONCENTRATION MEASUREMENT
M1141001100352
CAUTION
AIR HOSE
AC303612 AB
3 2 1
AC103195 AC
ENGINE COOLING
14-24
ON-VEHICLE SERVICE
AC303496AB
AC211776
! WARNING
Stay clear of the fan when the fan starts
running.
2
1
2
1
AC301712 AB
Battery
voltage
Terminal No.to
be connected
to tester
Continuity test
results
Not applied
42
Open circuit
Connect
42
terminal No.1
and battery ()
terminal.
Connect
terminal No.3
and battery (+)
terminal.
Less than 2
ohms
ENGINE COOLING
ON-VEHICLE SERVICE
2 1
AC303502AB
14-25
ENGINE COOLING
14-26
THERMOSTAT
THERMOSTAT
REMOVAL AND INSTALLATION
M1141002400442
<4G1>
22 4 Nm
6
3
AC203409 AC
<4G6>
1
13 2 Nm
6
3
1.
2.
<<A>> >B<<
3.
Removal steps
Water temperature gauge unit
connector <4G6>
Water temperature sensor unit
connector <4G6>
Radiator lower hose connection
4.
5.
6.
>>A<< 7.
AC301429 AD
ENGINE COOLING
14-27
THERMOSTAT
INSPECTION
M1141002500427
THERMOSTAT CHECK
Mating marks
AC200641AC
CAUTION
ACX00400 AB
Rubber ring
AC000279 AB
Mating marks
AC200642 AH
Valve lift
ACX00401AC
ENGINE COOLING
14-28
WATER PUMP
WATER PUMP
REMOVAL AND INSTALLATION <4G1>
M1141002700421
8 50
2
1
8 30
23 2 Nm
24 3 Nm
1.
>>A<< 2.
Removal steps
Alternator adjusting brace
Water pump assembly
ENGINE COOLING
14-29
WATER PUMP
N4
1
Bolt specifications
22 4 Nm
8 70
3N
23 3 Nm
8 22
8 14
8 25
14 1 Nm
8 22
Screw diameter length mm
AC301467AB
1.
2.
Removal steps
Alternator adjusting brace
Water pump assembly
Cooling water
line O-ring
3.
>>A<< 4.
ENGINE COOLING
14-30
13 N
7N
2
13 2 Nm
6
1
12
N8
13 2 Nm
10
5
11
AC203411AC
1.
2.
3.
<<A>> >>B<< 4.
5.
6.
Removal steps
Water temperature sensor unit
connector
Water temperature gauge unit
connector
Control wiring harness and harness
bracket
Radiator upper hose connection
Throttle body water feed hose
Thermostat case assembly
7.
>>A<< 8.
9.
10.
11.
12.
>>A<< 13.
ENGINE COOLING
14-31
CAUTION
Water pump or thermostat case
Cooling water
line O-ring
Mating marks
AC200641AC
Radiator upper
hose
Mating marks
Thermostat case assembly
AC200642 AI
ENGINE COOLING
14-32
9
8
9N
13 2 Nm
7
3
13 2 Nm
2
23 4 Nm
5
3 mm
3 mm
<<A>> >>C<< 1.
>>B<< 2.
3.
4.
>>B<< 5.
6.
Removal steps
Radiator upper hose connection
Cooling water outlet hose fitting
Throttle body water return hose
Throttle body water feed hose
Thermostat case assembly
Heater water hose connection
7.
8.
>>A<< 9.
ENGINE COOLING
14-33
Mating marks
AC200641AC
Radiator upper
hose
CAUTION
Water pump or thermostat case
Mating marks
Cooling water outlet
hose fitting
O-ring
AC200642 AJ
INSPECTION
M1141003400296
ENGINE COOLING
14-34
RADIATOR
RADIATOR
REMOVAL AND INSTALLATION
M1141001500468
12 2 Nm
14
5
12
20
1
10
10
15
18
17
6
7
AC303472 AB
ENGINE COOLING
14-35
RADIATOR
12 2 Nm
12 2 Nm
12
14
16
20
15
1
10
8
10
11
19
17
18
AC303473AB
<4G6>
12 2 Nm
12 2 Nm
12
14
3
4
15
1
10
13
17
7
1.
2.
3.
4.
<<A>> >>A<< 5.
<<A>> >>A<< 6.
7.
20
10
18
AC303474AB
ENGINE COOLING
14-36
RADIATOR
12.
15.
16.
17.
18.
19.
20.
Radiator hose
Mating marks
AC200641AC
Mating marks
Cooling water hose fitting
or thermostat case assembly
AC200642 AK