Page 905 of 3229

Stage 1:
Stage 2: Make s ure that new bolt s are ins t al led.
Inst all t he dri ves haft .
T orque: 40 Nm Inst all t he cool ant expans i on tank.
T orque: 10 Nm 9.
Secure t he engi ne wiring harnes s .
T orque: 10 Nm 10.
11. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Connect t he fuel li nes .
11.
Connect t he cool ant t op hos e.
12.
Connect t he cool ant bot tom hos e.
13.
Connect t he cool ing fan electrical connect or.
14.
Inst all t he RH halfs haft and s upport bracket.
T orque: 25 Nm 15.
Inst all t he LH halfshaft.
16.
W it h ass i st ance, i ns t all the hal fs haft t o t he hub.
17.
Inst all t he hal fs haft s .
T orque: 45 Nm 80°18.
19. CAUTION: A new O-ring s eal is t o be ins tall ed.
• NOTE: Lubri cat e t he O-ring s eals wit h clean refri gerant oil.
Connect t he A/C compress or high-press ure refri gerant line.
T orque: 24 Nm 19.
20. CAUTION: A new O-ring s eal is t o be ins tall ed.
• NOTE: Lubri cat e t he O-ring s eals wit h clean refri gerant oil.
Connect t he A/C compress or low-pres s ure refrigerant li ne.
T orque: 24 Nm 20.
Connect t he low pres sure li ne t o t he power s t eering pump.
21.
Page 906 of 3229

22. CAUTION: A new O-ring s eal is t o be ins tall ed.
Connect t he high-press ure power s t eering l ine t o t he power st eeri ng
pump.
T orque: 24 Nm 22.
Secure t he power s t eering hi gh-pres s ure l ine.
T orque: 10 Nm 23.
Inst all t he gear s elector cables .
24.
Connect t he brake boost er vacuum hos e.
25.
Connect t he ECM elect rical connectors .
26.
Inst all t he int ake ai r duct .
27.
Inst all t he charge air cool er inlet pipe.
T orque: 10 Nm 28.
Inst all t he front subframe.
Refer t o: Front Subframe (502-00 Uni -Body, Subframe and Mount ing
Syst em, Removal and Ins tall ati on).
29.
Inst all t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2L
Petrol, Removal and Ins tall ati on).
30.
Inst all t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculate Fil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removal
and Inst all at ion).
31.
Refi ll and bleed t he cool ing s ys tem.
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03B
Engine Cooli ng - TD4 2.2L Di esel , General Procedures ).
32.
Inst all t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -
I6 3.2L Pet rol, Removal and Ins t al lat ion).
33.
Inst all t he bat t ery t ray.
Refer t o: Bat t ery Tray (414-01 Bat tery, Mount ing and Cables ,
Removal and Ins tall ati on).
34.
Inst all t he plenum chamber access panel.
Refer t o: Plenum Chamber (412-01 Cl imat e Control, Removal and
Inst all at ion).
35.
Page 907 of 3229

Inst all t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
36.
Carry out the low-press ure fuel s ys t em bl eedi ng.
Refer t o: Fuel Syst em Bl eedi ng - TD4 2.2L Dies el (310-00 FuelSyst em - General Informati on, General Procedures ).
37.
Bleed t he clut ch sys t em.
Refer t o: Clutch Sys tem Bleeding (308-00 ManualTrans mi ss ion/Transaxle and Clut ch - General Informati on, GeneralProcedures ).
38.
Connect t he batt ery ground cable and ins tall t he cover.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
39.
Recharge the A/C sys tem.
Refer t o: Air Condi ti oning (A/C) Sys tem Recovery, Evacuati on andCharging (412-00 Cl imat e Control Sys t em - General Informat ion,General Procedures).
40.
Refi ll and bleed t he power st eeri ng.
Refer t o: Power St eering Sys tem Bleeding (211-00 St eering Sys tem -General Informat ion, General Procedures ).
41.
Carry out the fi nal halfshaft and sus pensi on ti ghtening wi th thevehicle on it s wheel s .42.
Page 908 of 3229

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Anti -freezeTexaco Ext ended Li fe Coolant (XLC) or any glycol bas ed anti -freezecontaini ng no met hanol wit h only Organic Acid Technology (O AT) corrosi oni nhi bit ors
Anti -freeze concentrati on - W i ll provi de frostprot ect ion to -40°C (-40°F)50%
Speci fi c gravit y of cool ant at 20°C (68°F), t oprot ect agains t fros t down to -40°C (-40°F)1.068
Amount of anti-freeze to use for 50%concentration:4.0 li ters
C apacitiesItemCapacity (liters/pints/US quarts)
Cooli ng sys t em capacit y8.0/14.0/8.5
General Specification
ItemSpecificationCooling fan:
St andard fi t - Single fan500W
Hot cli mate - Twin fan750WCooli ng sys t em t ypePress uris ed, t hermos t at icall y cont rol led wi th remot e header t ank
Expans ion tankSeeber wit h i nt egrat ed level s ens or
Radiat orVal eo 28mm core wit h i ntegrat ed drain cock and repl aceable lower pinThermos t atW ax element
St arts to open90° C
Full y open100° C
Torque Specifications
DescriptionNmlb-ftCoolant expans ion t ank bol t107
Coolant pump bolt s1713
Coolant pump pull ey bol ts107Radiat or bolt s65
Radiat or drain pl ug76
Thermos t at hous ing bolt s107W at er inlet pi pe bol ts1713
W at er inlet pi pe drain nipple75
W at er out let t o bl ock bolt107
Page 909 of 3229

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Des cript ion and Operat ion
COMPONENT LOCATION
OVERVIEW
Becaus e of it s powerful engine, s ophi s ti cat ed transmis si on and t racti on s ys t em; the vehicle in the mos t demandingcondi ti ons will need t o cont inuall y dis s ipate as much as 120 kW of heat t o atmos phere. To compound the s i tuati on t hi st ypi call y occurs at low speeds when t here i s ins ufficient air being forced t hrough the radiat or t o ai d the cooli ng s ys t em.W i th thi s in mind and consi dering that t he majorit y of vehi cl es rarel y need to dis s ipate more t han 10 kW of heat , thecool ing s ys tem has been s peciall y devel oped t o cope wit h t he s everit y of off-road dri vi ng and variable ext remes of cl imat e.
The cool ing s ys tem functi ons us ing the cros s -flow pri ncipl e. The coolant is routed from t he cool ant pump int o the engi neblock on t he exhaus t s ide of t he engi ne and leaves the engine bl ock at t he rear edge, vi a t he t hermos tat housi ng, on theint ake si de.
The t hermos tat is a wax t hermos tat . The cool ant t emperat ure s ensor i s located i n t he thermost at hous i ng.
The cool ant i s pumped from the coolant pump t o t he engi ne through 2 connecti ons . After pass ing through t he engine,s ome of t he coolant exit s t he engi ne block at the rear edge of t he exhaus t s ide t o be routed t hrough t he pass engercompartment el ement and onwards to the coolant pump.
Page 910 of 3229

ItemPart NumberDescription
1-Engine2-Thermost at
3-Cabin heat er core
4-By-pas s5-Radiat or
6-Vent uri exi t
7-Trans mi s si on oil cool er8-Coolant pump
9-Coolant expans ion tank
10-Engine oi l cooler
PRINCIPLES OF OPERATION
At idl e, and l ow out door t emperatures (l ower t han -10°C (14°F)) the engi ne's idle s peed i ncreas es from approxi mat el y 650rpm t o approximat el y 750 rpm. Thi s is to increase the coolant flow t hrough t he pass enger compart ment element, whi ch, i nt urn, makes it pos si ble t o i ncreas e t he heat in t he pas senger compartment . The coolant pump i s dri ven by the powers teeri ng pump t hrough a flange.
Coolant Flow - Closed Thermostat
Coolant leaves the engine bl ock vi a t he 2 circui ts at t he rear edge on t he int ake side of the engi ne.
The cool ant i s rout ed from one of t he circui ts to t he engine's oi l cooler and onwards t o t he cool ant pump.Coolant is routed from the ot her ci rcuit t o a 'by-pass ' circui t where t here i s a valve. The val ve is cl osed at engines peeds up t o approximat ely 1500 rpm. At approximat el y 1500 rpm, the valve opens and cool ant pas s es through t hecircuit . By keepi ng t he val ve clos ed at low engine speeds, a suffi ci ent flow is guarant eed through the pas sengercompartment el ement to obt ain a good cl imat e (suffi ci ent heat) in t he pass enger compart ment .
Page 911 of 3229

Coolant Flow - Open Thermostat
W hen t he t hermos tat opens, coolant is al so rout ed to the radiatorThe radi at or has an inl et on the Ri ght Hand (RH) s ide and 2 out let s on t he left-hand si deThe great er volume of cooled coolant is routed at the radi ator's l ower out let t o the coolant pumpAt t he upper outl et some of the coolant is routed t o t he automat ic t rans mi ss i on's oil cool er. Before t he coolantreaches the oi l cooler, it pas ses a 'choke' circuit t hrough t he radi at or wit h a lower (s lower) fl ow t han other cool ant s .This provi des opt imum cool ing of t he cool ant before i t reaches the oi l cooler, whi ch in turn, provi des effect ivecool ing of t he transmis s ion oil . The cool ant i s rout ed from t he oil cooler onwards to t he cool ant pump.
Bleeding
The engi ne has 2 bl eed ci rcuit s connected t o t he expans ion t ank. One is l ocat ed on the radiat or and the ot her on thecyl inder head.
Radiator and Cooling Fan(s)
The radi at or, whi ch di s si pat es heat from t he engine cool ant and engi ne mount ed oil cooler, i s manufactured from a 27 mmalumi num mat ri x wit h hi gh-pres s ure i nject ion molded end t anks .
ItemPart NumberDescription
A-Col d t o mi ld cli mat e radiat orB-Hot cl imat e radi at or
Dependant on cli mate condit ions t here are 2 s peci fi cat ions of radiat or fan avail abl e:
Cold t o mild cl imat es : a s ingle fan unit des igned around a 500W mot orHot climat es : a t win fan unit feat ures t wo motors del iveri ng a t otal of 750W
Common t o bot h fan types are:
Electric mot ors wit h brus hesThe Engi ne Control Module (ECM) controls t he fan speed via Pul s e W i dth Modulat ion (PW M) s i gnal s to the El ect ronicFan Cont rol Module (EFCM)The fan speed i s cont rol led at 4 l evel s:- Run-on occurs i n 3 s t ages (i.e. depres s ing the fan s peed)- The engine cool ing fan i s act ivated a cert ai n t ime aft er t he engine has been s wit ched off to prot ect vari ousengi ne component s from overheati ng- The t ime the fan is act ivated and the s peed of the fan i s dependent on the coolant t emperature and thedri ver's driving s t yle (engi ne load) when t he engi ne is swi tched off- The hott er the engine and the hot ter t he load, the hi gher t he fan speed and t he longer run-on ti me. The
Page 912 of 3229
maximum t ime of run-on i s 360 s econdsThe EFCM can, by modul at ing the PW M control s i gnal, i nform t he ECM about the fan's st at us and any faul ts .
PW M cont rol of the fan mot or provides variabl e cont rol of fan speed t o ensure mi nimum fan noi se and reduced energycons umpt ion when fan operati on is required. The cont rol module is mount ed above the wade wat er ent ry li nesFor addit ional informat ion, refer t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol ,Des cript ion and Operat ion).
The cool ant expansi on tank provi des an expans ion volume and permit s eas y in-s ervice bleeding of t he cool ing s ys tem.Coolant level s ens ing i s precis e t o provide early warning i n t he event of low cool ant l evel . To prevent i ntrusi on int o t heexpans ion t ank's cas i ng, whi ch could be a potent ial leak path, a magnet ic float wi thin the t ank act ivat es a s wit ch locatedouts ide the t ank.