Page 3172 of 6020

Engine Cooling – V6 Engine Page 6B1–37
Test
1 W ith the thermostat (1) installed in the housing,
suspend it and a suitable thermometer (2) in a
container of 50% clean fresh water and 50% Dexron ®
long life coolant, (conforming to GM 6277M).
NOTE
Neither the thermostat assembly (1) nor the
thermometer (2) 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
temperature and ensure thermostat opens within
specified temperature range.
Thermostat Opening Specifications
Opening Temperature ........................................ 82 ° C
Fully Open Temperature .................................... 95 ° C
3 Replace thermostat if it does not meet these operating
conditions.
Figure 6B1 –
––
–
39
Dismantle
Only dismantle the thermostat if a reverse
flushing operation of the cylinder block is to
be carried out. If the testing operation
indicates that the thermostat is faulty, then
the housing and thermostat are only serviced
as an assembly.
Remove thermostat (1) from thermostat housing (2) as
follows:
a Secure the thermostat housing by gripping in a vice fitted with soft jaws.
Always wear protective safety glasses when
working with spring-loaded devices. Failure
to do so could result in eye injury.
b Depress the retaining bar (3) on both sides of the thermostat and rotate the thermostat until it
clears the retaining lugs (4) on the thermostat
housing (2).
c Release the thermostat spring force.
d Remove the thermostat assembly from the thermostat housing.
Figure 6B1 – 40
Reassembly
The reassembly process is the reverse to that used for disassembly, with the following exceptions:
1 Check that the valve sealing surface is undamaged.
2 W ipe the valve sealing surface to ensure a clean surface.
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Engine Cooling – V6 Engine Page 6B1–40
2 Check coolant recovery system for leaks.
3.10 Coolant Pump
Remove
Refer to 3.1 Service Notes in this Section, for
important safety items.
NOTE
The coolant pump is not to be disassembled and
is replaced only as an assembly.
1 Allow engine to cool to ambient temperature (less than 50 ° C), and then remove the coolant filler cap (located at
the front left-hand side of the engine).
Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis.
3 Loosen coolant pump pulley to hub bolts (1).
NOTE
While the view shows the drive belt removed,
it will be easier to loosen the four pulley bolts,
with the belt installed.
Figure 6B1 – 42
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Page 3180 of 6020

Engine Cooling – V6 Engine Page 6B1–45
3.11 Coolant Outlet Housing
Remove
Refer to 3.1 Service Notes in this Section, for
important safety items.
1 Allow engine to cool to ambient temperature (less than 50 ° C), and then remove the coolant filler cap (located at
the front left-hand side of the engine).
Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis Battery.
3 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System.
4 Remove the complete intake manifold assembly. Refer to 6A1 Engine Mechanical.
Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
5 Remove upper radiator hose clamp (1) at the coolant outlet housing connection (2), disconnect
hose from coolant outlet.
Figure 6B1 – 50
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Engine Cooling – V6 Engine Page 6B1–46
6 Remove the two coolant outlet housing attaching
bolts (1), and remove coolant outlet housing (2).
7 Remove and discard coolant outlet housing O-ring (3) and seal (4).
Figure 6B1 – 51
Reinstall
1 Ensure that the coolant outlet housing and front outlet mating surfaces are clean and dry.
2 Install new O-ring and seal to coolant outlet housing.
3 Install coolant outlet housing and attaching bolts. Tighten all bolts to the correct torque specification.
Coolant outlet housing to front
outlet bolt torque specification..............................10 N.m
Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
4 Connect the upper radiator hose and clamp to the coolant outlet housing connection.
5 Close the radiator drain tap on the lower RHS of the radiator and remove the piece of rubber tubing to the tap outlet.
6 Reinstall the intake manifold assembly. Refer to 6A1 Engine Mechanical.
7 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
8 Check for coolant leaks. Refer to 3.7 Pressure Testing in this Section.
9 Reconnect battery ground lead. Refer to 8A – Electrical Body & Chassis.
3.12 Coolant Inlet Pipe
Remove
Refer to 3.1 Service Notes in this Section, for
important safety items.
1 Allow engine to cool to ambient temperature (less than 50 ° C), and then remove the coolant filler cap (located at
the front left-hand side of the engine).
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Engine Cooling – V6 Engine Page 6B1–47
Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis.
Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
3 Draining the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this Section.
4 Raise the front of the vehicle and support on safety stands. Refer to 0A General Information for the location of jacking and support points.
Always wear protective safety glasses when
working with spring type hose clamps.
Failure to do so could result in eye injury.
5 Remove lower radiator outlet hose clamp (1) at the coolant inlet pipe connection, then disconnect the
hose from coolant inlet pipe (2).
6 Remove the coolant inlet pipe from the engine block by removing the attaching bolt (3).
Figure 6B1 –
––
–
52
7 Remove the coolant inlet pipe (1) to thermostat housing (2) attaching bolt (3).
8 Remove the coolant inlet pipe by manoeuvring the pipe to the front of the vehicle and withdrawing the
pipe from below the vehicle, between the cross
member and radiator.
9 Remove and discard coolant inlet pipe O-ring (4) from the thermostat end of the coolant inlet pipe.
Figure 6B1 –
––
–
53
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Engine Cooling – V6 Engine Page 6B1–51
Disassemble
1 Remove cooling fan and shroud assembly as previously described.
NOTE
Neither fan is to be separated from its fan motor.
The assembly is carefully balanced during
manufacture and duplicating this balance on
reassembly, is not possible.
2 Remove the motor assembly wiring harness (1) from the integral clips that form a part of the shroud (2).
3 Remove screws (3) attaching the motor assembly (to the shroud, then remove each motor, fan and wiring
assembly (4) from the shroud.
Figure 6B1 –
––
–
58
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 N.m
2 Ensure that all wiring is routed correctly and secured by the shroud clips.
3 Install cooling fan and shroud assembly to the radiator, as previously described.
3.14 Flexible Transmission Cooler Hose
Replace
NOTE
The flexible hoses are not serviced separately.
Therefore, should a hose require replacement,
then the hose and radiator to hose cooler pipe
assembly must be fitted.
1 Place a drip tray beneath the engine and radiator section.
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Engine Cooling – V6 Engine Page 6B1–54
3.15 Radiator
Remove
Refer to 3.1 Service Notes in this Section, for
important safety items.
1 Allow engine to cool to ambient temperature (less than 50 ° C), then remove coolant filler cap.
Disconnection of the battery affects certain
vehicle electronic systems. Refer to 00
Warnings, Cautions and Notes, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis.
3 Depress the tang on the main wiring harness to the cooling fan motor wiring harness connector (1) and
separate the connector.
4 Remove the radiator cooling fan and shroud assembly. Refer to 3.13 Cooling Fan and Shroud
Assembly in this Section.
5 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this
Section.
Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the
coolant.
Figure 6B1 – 62
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Page 3194 of 6020

Engine Cooling – V6 Engine Page 6B1–59
General Core Repair
NOTE
The need for careful preparation of the surface in
the repair area cannot be over-emphasised. If the
leak area surface is not clean, the repair material
will not adhere to the surface.
Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
1 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this Section.
2 Remove the radiator. Refer to 3.15 Radiator in this Section.
3 If necessary, carefully cut away fins to expose the damaged area.
NOTE
Do not cut away more than 25 mm total fin
material.
4 Clean away dirt etc. with water. Dry the affected area using hot air from a hair drier.
Do not apply flame to dry damaged area.
5 Clean affected area with petrol to remove any traces of oil.
6 Thoroughly stir contents of repair agent.
NOTE
In cases of extended shelf life, the silicon in
solution may separate from the thinner base.
Should this occur, mix contents well until agent is
again homogeneous.
7 Apply repair agent sparingly to damaged area. Do not apply an excessive amount, as this will cause blockage of the radiator tube.
NOTE
Use a clean, dry wooden applicator to 'DRIP'
agent onto damaged area of radiator.
8 Allow radiator to stand in a clean, dry area for a minimum of 3 hours (at ambient temperature of 20 – 30 ° C) with
adequate ventilation.
NOTE
Do not apply heat or flame to promote drying.
9 Reinstall the radiator. Refer to 3.15 Radiator in this Section.
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