ENGINE COOLING SYSTEM

2112-01/1520-01/2130-13/1520-11/1431-07/1411-01/
9210-05/2130-01/1333-15/1520-11/1333-14/1412-01

ENGINE COOLING SYSTEM

GENERAL REMOVAL AND INSTALLATION

1. ENGINE COOLING SPECIFICATIONS... 3 9210-05 TROUBLE DIAGNOSIS................ 22

9210-05 COOLANT LEVEL CHECK........... 23
9210-05 INSPECTION AND REPAIR.......... 24
9210-05 DRAINING AND ADDING OF
OVERVIEW AND OPERATION COOLANT.................................... 26
PROCESS 2130-01 COOLANT
HOSE(INLET/OUTLET)................ 27
1. COMPONENTS OF ENGINE COOLING. 1333-15 SHROUD AND COOLING
4
2. COOLING SYSTEM FLOW..................... FAN/CLUTCH............................... 29
5
3. FUNCTION DESCRIPTION OF 1520-01 WATER PUMP ASSEMBLY......... 31
COOLING SYSTEM............................... 1520-11 THERMOSTAT............................ 34
6
1520-01 WATER PUMP HOUSING............. 36
2112-01 RADIATOR................................... 38
1333-14 REPLACEMENT OF FAN BELT... 44
9210-05 COOLANT RESERVOIR.............. 46
CONFIGURATION AND FUNCTIONS 1412-01 PREHEATING.............................. 47
1412-01 PREGLOW PLUG......................... 48
2112-01 RADIATOR................................... 7
1520-01 WATER PUMP............................. 8
2130-13 COOLANT RESERVOIR............... 9
1520-11 THERMOSTAT............................ 10
1431-07 COOLANT TEMPERTURE
SENSOR...................................... 14
1411-01 PREHEATING SYSTEM............... 16
 2112-01 07-3

ENGINE COOLING SYSTEM 9210-05

GENERAL
1. ENGINE COOLING SPECIFICATIONS

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OVERVIEW AND OPERATION PROCESS

1. COMPONENTS ENGINE COOLING
Coolant Reservoir FFH Water Pump

Cooling Fan and Coolant

Radiator Assembly
Fan Clutch Temperature Sensor

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2. COOLING SYSTEM FLOW

PTC Engine Coolant Flows

FFH Engine Coolant Flows

- Cylinder block side

· Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump
- Cylinder head side
· Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump

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3. FUNCTION DESCRIPTION OF COOLING SYSTEM

Intake
manifold

Cylinder
head

Coolant
outlet port

- Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1)
· Improved shape and gasket material to prevent coolant from leaking

- In OM 600 engine, coolant inflows through the heater line rear section (cylinder #4 and #5)
of cylinder head.
However, in D27DT engine, coolant inflows from cylinder block through oil cooler (refer to
coolant flows layout in previous page).
· It prevents cooling efficiency from decreasing due to coolant separation between
cylinder #4 and #5.
- In OM 600 engine, the cooling fan is installed with water pump, however, in case of
D27DT engine, it is connected to water pump with an additional pulley.

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CONFIGURATION AND FUNCTIONS

2112-01 RADIATOR
This vehicle has a lightweight tube-and-fin
aluminum radiator. Be careful not to damage
the radiator core when servicing.

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1520-01 WATER PUMP

The belt-driven centrifugal water pump
consists of an impeller, a drive shaft, and a
belt pulley. The impeller is supported by a
completely sealed bearing. The water pump
is serviced as an assembly and, therefore,
cannot be disassembled.

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2130-13 COOLANT RESERVOIR

- Scalding hot coolant and steam could

be blown out under pressure, which
could cause serious injury.
Never remove the coolant reservoir
cap when the engine and radiator are
hot.

The coolant reservoir is a transparent plastic reservoir, similar to the windshield washer
reservoir. The coolantreservoir is connected to the radiator by a hose and to the engine cooling
system by another hose. As the vehicle is driven, the engine coolant heats and expands.The
portion of the engine coolant displaced by this expansion flows from the radiator and the engine
into the coolant reservoir. The air trapped in the radiator and the engine is degassed into the
coolant reservoir.
When the engine stops, the engine coolant cools and contracts. The displaced engine coolant
is then drawn back into the radiator and the engine. This keeps the radiator filled with the
coolant to the desired level at all times and increases the cooling efficiency. Maintain the
coolant level between the MIN and MAX marks on the coolant reservoir when the system is
cold.

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1520-11 THERMOSTAT

A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling
system. The thermostat is mounted in the water pump housing. The thermostat stops the flow of
the engine coolant from the engine to the radiator to provide faster warm-up, and to regulate the
coolant temperature. The thermostat remains closed while the engine coolant is cold,
preventing circulation of the engine coolant through the radiator. At this point, the engine
coolant is allowed to circulate only throughout the heater core to warm it quickly and evenly. As
the engine warms, the thermostat opens. This allows the engine coolant to flow through the
radiator where the heat is dissipated. This opening and closing of the thermostat permits
enough engine coolant to enter the radiator to keep the engine within proper engine
temperature operating limits. The wax pellet in the thermostat is hermetically sealed in a metal
case. The wax element of the thermostat xpands when it is heated and contracts when it is
cooled. As the vehicle is driven and the ngine warms, the engine coolant temperature
increases. When the engine coolant reaches a specified temperature, the wax pellet element in
the thermostat expands and exerts pressure against the metal case, forcing the valve open.
This allows the engine coolant to flow through the engine cooling system and cool the engine.
As the wax pellet cools, the contraction allows a spring to close the valve.
The thermostat begins to open at 85°C and is fully open at 100°C. The thermostat closes
at 85°C.

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▶ When closed (up to 85°C)

X. from cylinder head
Y. to crankcase
Z. from radiator

▶ When partially opened (85°C ~ 100°C)

▶ When fully opened (above 100°C)

If the cooling system is fully filled with, the coolant is automatically bled through ball valve
(arrow) in thermostat.

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▶ Viscous fan clutch

NO. FUNCTION NO. FUNCTION

1 Clutch housing 9 Pin
2 Drive disc 10 Bi-metal
3 Flange 11 Bracket cover
4 Seal ring 12 Separator disc
5 Needle bearing 13 Supply port
6 Cooling fan 14 Lever valve
7 Oil scraper 15 Oil chamber
8 Spring 16 Operating chamber

The cooling speed increases approx. 1,000 rpm with wind noise when the engine speed is
4,000 to 4,500 rpm and the coolant temperature is 90 to 95°C.

- Keep hands, tools, and clothing away from the engine cooling fans to help prevent
personal injury.
This fan is electric and can turn on even when the engine is not running.

- If a fan blade is bent or damaged in any way, no attempt should be made to repair or
reuse the damaged part.
A bent or damaged fan assembly should always be replaced with a new one to prevent
possible injury.

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The cooling fans are mounted behind the

radiator in the engine compartment. The
electric cooling fans increase the flow of air
across the radiator fins and across the
condenser on air conditioner. The fan is 320
mm in diameter with five blades to aid the
airflow through the radiator and the
condenser. An electric motor attached to the
radiator support drives the fan.

- A/C Off or Non-AC Model

· The cooling fan operates at low speed when the coolant temperature reaches 95°C
and at high speed when the coolant temperature reaches 100°C.
· The cooling fan is turned from high speed to low speed at 97°C and turns off at
90°C.
- A/C On
· The ECU will turn the cooling fan on at high speed when the A/C system is on.

▶ Engine coolant temperature sensor

The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal
voltage to the Engine Control Unit (ECU).

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1431-07 COOLANT TEMPERTURE SENSOR

Output Characteristics of Coolant
Coolant Temperature Sensor
Temperature Sensor

Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so
the ECU detects lowering signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very
well. However, if engine temperature is too low, the fuel injected as foggy state forms big
compounds causing incomplete combustion. So the sensor detects coolant temperature and
changes coolant temperature changes into voltage then sends to ECU to increase the fuel
volume during cold start for better starting. And detects engine overheating for fuel volume
reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
- When engine is cold, controls fuel volume to correct idle speed
- When engine is overheated, controls electrical fan and A/C compressor to protect the
engine
- Sends information for emission control

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Coolant Temperature Sensor Circuit

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1411-01 PREHEATING SYSTEM

Glow plug
Preheat relay

Battery

ECU Glow Indicator (Meter Cluster)

Tightening torque
when installing
15 ± 3 Nm

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NO. FUNCTION
1 Glow plug terminal (#1 ~ #4)
No G5 for 4 cylinders
2 (Without D20DT)
3 IG1 power supply terminal
4 Glow plug control signal (ECU113)
5 Ground terminal
6 Battery main wire
Preheat completion transmit
7 terminal : No use for vehicle
without remote engine start
8 K-line (ECU 34)

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1) Overview
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating
control unit system. Cold starting performance has improved and exhaust gas during cold
starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine
preheating/post heating and glow plug diagnosis function, the fault contents will be delivered to
ECU.
- Engine preheating/post heating functions
- Preheating relay activation by ECU controls
· Senses engine temperature and controls the preheating/after heating time
· Glow indicator
- K-LINE for information exchanges between preheating unit and ECU
· Transmits preheating unit self-diagnosis results to ECU
· Transmits glow plug diagnosis results and operating status to ECU

2) Preheating Relay
▶ Structure

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3) Preheating System Diagram

4) Specifications

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5) Function
Preheating system controls and checks following functions and operating conditions.

(1) Pre-Heating
- The power will be supplied to the glow plugs by ECU controls when the power is
supplied to the IG terminal from the battery and there are normal communications with
ECU within 2 seconds. The surface of glow plug will be heated up to 850°C very
quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
- Preheating time is controlled by ECU.
(2) Post-heating
- When the engine is started, post-heating starts by ECU controls. The idle rpm will be
increased to reduce
toxic smoke, pollutants and noises.
- Post-heating time is controlled by ECU.

(3) Checking glow plugs

- Check each glow plug for short in circuit
- Check each glow plug for open in circuit due to overvoltage
- Check glow plug for short to ground

(4) Forceful relay shut-down

- When glow plug is shorted to ground

(5) K-Line communication

- ECU sends the results to preheating time control relay through K-Line to start
communication.
- Preheating time control relay sends messages including self-diagnosis data for glow
plugs to ECU.
- Glow plug makes communication only as response to demand.
- When power is supplied, ECU starts self-diagnosis within 2 seconds.
- Under the following conditions, communication error occurs.
· When there is no response from glow plug module within 2 seconds
· When an error is detected in checksum
· Less byte is received

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(6) DTC

(7) Operating time

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REMOVAL AND INSTALLATION

9210-05 TROUBLE DIAGNOSIS

ENGINE COOLING SYSTEM

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9210-05 COOLANT LEVEL CHECK

- Scalding hot coolant and steam could be blown out under pressure, which could cause
serious injury. Never remove the coolant reservoir cap when the engine and radiator are
hot.
- Take precautions to prevent antifreeze coming in contact with the skin, eyes or vehicle
body. If contact happens, rinse affected areas immediately with plenty of water.

1. Place the vehicle on a level ground and check the coolant level through the coolant reservoir.
2. Add if needed. Change the coolant if necessary.

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9210-05 INSPECTION AND REPAIR

1) Inspection
(1) Cooling system
1. Release the pressure from coolant
reservoir by loosening one notch of
coolant reservoir cap, and then remove
the cap.

- Scalding hot coolant and steam could be

blown out under pressure, which could
cause serious injury. Never remove the
coolant reservoir cap when the before
the temperature goes down below 90°C.

2. Add the coolant up to upper mark (arrow)

on the reservoir.
3. Install the tester to the coolant reservoir
and apply the pressure of 1.4 bar.
4. Check the coolant hoses, pipes and
connections for leaks after the pointer of
the tester drops.
Replace or retighten as required.

(2) Thermostat

Temperature gauge Immerse the thermostat into the water. Heat

the water and check the valve opening
temperature.

Valve opening DI Engine:

temperature 85 ± 2°C

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(3) Coolant temperature gauge unit

1. Immerse the senor unit into the water.
Heat the water and check the resistance.

2. If the measured resistance is out of

specified value, replace the gauge unit.
3. Measure the resistance between terminal
A and gauge unit housing, and terminal B
and gauge unit housing.

Terminal A 0.4 Ω / 79°C

(for coolant temp) 23.8 Ω / 115°C

Terminal B 24.8 Ω / -20°C

(for glow plug) 3.25 Ω / 20°C

(4) Thermostat
1. Immerse the thermostat into the oil. Heat
the oil until it reaches the specified
temperature and check if the coolant
temperature switch is turned "OFF".
Coolant temperature at
113 ± 3°C
point A
Coolant temperature at
116°C
point B

- Use only engine oil for this inspection.

Stir the oil during heating it. Never heat
the oil over required temperature.

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9210-05 DRAINING AND ADDING OF COOLANT

1. Release the pressure from coolant
reservoir by loosening one notch of
coolant reservoir cap, and then remove
the cap.

- Scalding hot coolant and steam could

be blown out under pressure, which
could cause serious injury. Never
remove the coolant reservoir cap when
the before the temperature goes down
below 90°C.

2. Loosen the drain plug in bottom of

radiator and drain the coolant.

- Collect the drained coolant with a proper

container.

3. Remove the drain plug and seal in the

cylinder block and drain the coolant.
4. Replace the seal with new one and
install the drain plug.
30 Nm

5. Install the drain plug in bottom of radiator.

6. Add the coolant through the coolant
reservoir.

- Keep the coolant mixture ratio of 50:50

(water : antifreezer).
- Add the coolant until the water flows out
through the overflow hose.

7. Warm up the engine until the thermostat

begins to open and check if the coolant
level is at "FULL" mark on the reservoir.
Add if necessary.

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2130-01 COOLANT HOSE(INLET/OUTLET)

1. Draining of coolant

1. Loosen the clamp and remove the

coolant outlet hose (engine to radiator).

2. Disconnect the HFM sensor connector.

3. Remove the air intake duct from the air
cleaner.

4. Loosen the clamp and remove the

coolant inlet hose
(radiator to thermostat housing).

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5. Lift up the vehicle and remove the skid

plate.
6. Loosen the clamp and remove the lower
inlet hose.

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1333-15 SHROUD AND COOLING FAN/CLUTCH

1. Draining of coolant
2. Removal of coolant inlet and outlet hose

1. Remove the air cleaner duct.

2. Release the clamps and remove the

intake hose.
3. Unscrew the fan shroud mounting bolts.

4. Unscrew the center bolt and remove the

cooling fan clutch while holding the pulley
with counter holder (special tool).
45 ± 4.5 Nm

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5. Remove the shroud.

6. Install in the reverse order of removal.

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1520-01 WATER PUMP ASSEMBLY

1. Draining of coolant
2. Removal of V-belt
3. Removal of shroud
4. Removal of cooling fan

NO. FUNCTION NO. FUNCTION

1 Thermostat housing 4 Belt pulley
2 Gasket ............................... Replace 5 Bolt ........................................ 10 Nm
3 Bolt ........................................ 10 Nm 6 Water pump bearing housing

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1. Remove the V-belt while pressing down

the auto tensioner adjusting bolt.

2. Unscrew the bolts and remove the EGR

pipe and bracket.
23 ± 2.3 Nm

3. Unscrew the bolts and remove the belt

pulley while holding the belt pulley with a
special tool.
10 Nm

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- Replace the O-ring in oil dipstick with

new one.
- Plug the oil dipstick hole with a cap not
to get the foreign materials into the
engine.

5. Unscrew the bolts and remove the water

pump assembly.
10 Nm

- Remove the gasket residues from the

sealing surface and replace the gasket
with new one.

6. Install in the reverse order of removal.

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1520-11 THERMOSTAT
1. Draining of coolant
2. Removal of V-belt
3. Removal of cooling fan
4. Removal of intake duct (air cleaner to turbo charger)

NO. FUNCTION NO. FUNCTION

1 Gasket ............................... Replace 4 Thermostat
2 Water pump housing 5 Seal
3 Bolt ........................................ 10 Nm 6 Coolant hose

1. Unscrew the bolts and remove the

hermostat housing.
10 ± 1.0 Nm

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2. Remove the thermostat.

3. Install in the reverse order of removal.

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1520-01 WATER PUMP HOUSING

1. Removal of water pump
assembly
2. Removal of thermostat
assembly
1. Remove the heater hose.

2. Unscrew the bolts and remove the

alternator.
46 ± 4.6 Nm

3. Unscrew the bolts and remove the

alternator bracket.
25 ± 2.5 Nm

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4. Unscrew the bolts and remove the water

pump housing.
10 ± 1.0 Nm

- Be careful not to damage the O-ring in

coolant outlet pipe (cylinder head side).
- Remove the gasket residues from the
sealing surface and replace the gasket
with new one.

5. Install in the reverse order of removal.

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2112-01 RADIATOR
1) Components of Radiator Module
▶ Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
1. Disconnection of negative battery cable
2. Removal of front bumper assembly
3. Discharge of refrigerant
4. Draining of engine coolant

2) Removal Procedure

Intercooler Electric Fans

Radiator Condenser

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3) Removal and Installation

1. Collect the refrigerant from
A/C system.
2. Remove the lower cover.
3. Drain the engine coolant into
the designated container.

- Store the refrigerant and engine coolant

in a safe place.

1. Remove the air cleaner duct.

LH 2. Disconnect the intercooler hoses.

6 ~ 7 Nm
RH

6 ~ 7 Nm

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3. Remove the inlet, outlet and return hoses.

Inlet Hose Return Hose Outlet Hose

4. Remove A/C hose and condenser pipe.

- Plug the openings of the pipes with sealing caps.

High Pressure Pipe: Low Pressure Pipe:

compressor side receiver drier side

16 ~ 23 Nm

5. Unscrew the bolts and remove the radiator

brackets.

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6. Remove the transmission oil cooler pipes.

25 ~ 35 Nm

7. Pull out the fixing clips and remove the

radiator.

8. Remove the outlet pipe from the intercooler. 6 ~ 7 Nm

Release the clamp Remove two bolts

(10 mm)

6 ~ 7 Nm

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9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the
radiator.

Intercooler Assembly

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10.Remove the T/M oil cooler pipes from the radiator.

11.Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

Condenser

Radiator

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1333-14 REPLACEMENT OF FAN BELT

1. Disconnect the negative battery cable.

1. Turn the fan belt adjusting bolt (19 mm) counterclockwise.

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2. Remove the fan belt.

Fan Belt Arrangement

D20DT

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9210-05 COOLANT RESERVOIR

1. Drain the coolant.
2. Remove the hoses.

3. Unscrew the bolts and remove the

coolant reservoir.
7 Nm

4. Install in the reverse order of removal.

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1412-01 PREHEATING
1. Turn the ignition switch to "OFF" position
and disconnect the negative battery
2. cable.
Set aside the harnesses on the cylinder
head.

3. Disconnect the glow plug connectors and

loosen the glow plugs.
15 Nm

4. Remove the glow plugs from the cylinder

head with a special tool. Plug the
openings of the glow plugs with sealing
caps.

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1412-01 PREGLOW PLUG

Two versions of preglow plugs are used in this vehicle.
Always use only the designated version with correct color mark on insulator surface.

1) Specifications
BERU version NGK version

Color mark on insulator surface: Green Color mark on insulator surface: Yellow
Tip diameter: φ 4 Tip diameter: φ 3.5
Resistance: 680 ± 110 mΩ at 20 ± 2ºC Resistance: 1400 ± 300 mΩ at 20 ± 2ºC

Green Yellow

The color mark on insulator surface may be invisible due to the carbon contamination. To check
the color easily, disconnect the harness connector and clean the preglow plug mounting area
with carbon cleaner. Wait for a while and blow out the area with a compressed air.

Clean and Blow Out Check the Color Mark

Air gun Check the color mark

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2) Preparations for Replacing Preglow Plug

Torque wrench, Air gun (small), Carbon cleaner (Product name: IPO CHOKE & CARBURATOR
CLEANER, Model name: PRO NO 5007, Manufacturer: Sunbo), Engine oil, Preglow plug
wrench (special service tool), Long nose pliers

3) Removal and Installation of Preglow Plug

1. Disconnect the negative battery cable.

1. Disconnect the wiring harness with long nose pliers and clean the preglow mounting area
with the compressed air (using air gun).

Air gun

2. Spray the carbon cleaner into the gap between preglow plug and cylinder head and wait for
10 minutes. Remove the dirt and foreign materials completely with the compressed air
(using air gun).

- At this moment, check the color mark on insulator surface and bring the same version of
preglow plug for replacement. (BERU: Green, NGK: Yellow)

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3. To avoid damage, apply the engine oil into the gap between preglow plug and cylinder head
and wait for 5 minutes.

4. Remove the preglow plug with torque wrench. (tightening torque: 15 ± 3 Nm)

- To prevent the preglow plug from breaking, carefully turn the wrench with the torque
below 20 Nm.
- Never use the air impact tool or other tools.

5. Thoroughly remove the foreign materials from the preglow plug hole. If needed, use the
carbon cleaner or air gun.

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4) Remarks
1. Required tools

Carbon Cleaner Torque Wrench (max. 25 Nm)

Preglow plug wrench - Special Service Tool

(10 mm) Part number: Y99220132B

2. Preglow plug circuit check

1) Check the preglow plug trouble code with SCAN-100.
2) SCAN-100 can display only one trouble code. Check whether each preglow plug circuit is
open with multitester.

Color mark on BERU: Green

insulator surface NGK: Yellow

Tip diameter BERU: 4 mm

NGK: 3.5 mm

ENGINE COOLING SYSTEM

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