COOLING SYSTEM 164 COOLING SYSTEM TABLE OF CONTENTS COOLING SYSTEM senssu Description System operation... Draining of the hydraullc system .. Servicing of the hydraullc system. HEADER TANK = Removal/instaltation 07-5 + Pressurized cap seal test 07-5 + Hydraulic system proof test 07-5 PUMP AND THERMOSTAT UNIT + Removaliinstallation + Disassembly/Reassemb! + Checks and inspections. RADIATOR + Removalrinstaltation + Disassembly/Reassemb! saemes OF 10 + Radiator proot test ENGINE COOLANT ELECTRIG FAN sssessus 07-10 RADIATOR FAN THERMAL SWITCH > Checks and Inspections o7e11 o7-44 COOLANT/OIL HEAT EXCHANGER. + Removalinstallation .. + Checks and inspections o7-41 07-12 07-12 TECHNICAL CHARACTERISTICS AND SPECIFICATIONS + Fluids and lubricants + Tightening torques. + Special tools 07-13 07-13 07-14 07-14 TROUBLESHOOTING PROCEDURE. 07-15 o7-1= COOLING SYSTEM ILLUSTRATED INDEX MEADER TANK (rege 07-0) RADIATOR (pags 07-9) REMOVALINSTALL (age REMOVALINSTALL (page 07-9) wun COOLANT PRESSURED CAP sent resr a DISASSEMBLY-REASS, (pogo 07-10; LEVEL WARNING LAMP HYDRAULICS ‘TEST nage 7 RADIATOR PROOF TEST (page 07-10) en Bese toe meer REE (COOLANT TEMPERATURE GAVOE, roay"T ty 280 Si ‘CHECKS AND INSPECTIONS {page 07-12) WATER PUMP AND THERMOSTAT UNT (page 07-6 1AX. COOLANT REMOVALANSTALLATION (page 07-7) WARNING LAMP SENSOR \ CISASSEMBLYREASSENELY (page 07 -8) MAX COOLANT TEMPERATURE (CHECKS AND INSPECTIONS (page 07-8) “WARNING LAMP 07-2COOLING SYSTEM isa COOLING SYSTEM DESCRIPTION ‘The cooling systemis of the sealed type. The coolant flow is forced by a centrifugal pump driven by the crankshaft through a poly-V type belt. A thermostat maintains the engine temperature within optimum values; the thermostat opens when the coolant temperature reaches about 87°C (188°F). The coolant is cooledin the radiator by means of ram air effect and by a two-speed electric fan controlled by a ra- diator mounted thermal switch; an additional resistor and a relay select the higher speed af the electric fan in case of excessive temperature. ‘The headertanktops-up the coolingsystemin case of ow coolant level, and absorbs the changes of coolantvolume due to changes in temperature; the header tank also enables to bleed the air from the system. The cooling system also includes a coolant temperature sensor which contro!sihe maximumtemperature waming lamp onthe instrument panel. The warning lamp turns on when the coolant temperature increases above 115°C (299°F). A turther sensor on the header tank monitors the coolant minimum level and directs level signals to the relevant warming lamp on the instrument panel. SYSTEM OPERATION After the engine has been cooled, the coolant flows 10 the thermostat unit. If the temperature Is below 87°C (188°F) the coolant is directed to the pump; it the temperature is above the limit value, the coolant is directed to the radiator, Aller cooling, the coolant retumns to the pump and is then directed to the engine. Moreover, a cooling system offtake maintains the throttle body to a constant temperature; a second offtake is also Provided to cool the engine oil through a heat exchanger located below the oil iter. ‘Two vent pipes connect the highest points of the system (radiator and throttle body) to the header tank, and allow bleeding in the header tank of any air thal could be trapped in the system. A further offtake supplies the air conditioning heater, which provides heating of the vehicle interior (refer to Group 80). CAUTION: The anti-freezing mixture is harmful for the paintwork. Avoid any contact with painted ‘surfaces. DRAINING OF THE HYDRAULIC SYS- TEM 4. Disconnect (-} lead from the battery. 2. Unscrew and remove header tank cap. WARNING: Do not absolutely remove the header tank cap while the engine Is warm. 3. Loosen clamp fixing the radiator outlet sleave, and disconnect sleeve from the radiator; drain andi collect coolant in a suitable container located underneath the vehicle. RADIATOR 07-33 SYSTEI COOLING SYSTEM 164 SERVICING OF THE HYDRAULIC pay It Is recommended not to mix anti-freeze 1." Connect radiator sleave and any other hose previ- thulds of ditterent types or brands. ously disconnected; check that all clamps are prop- erly tightened. 2. Service the system to the MAX tevel mark on the header tank. ‘The type and approximate quantity of coolant are in- dicated in the table below: 1 Disttlled water 87 (Dilution) 2.35 Antl-treeze mixture (Ready for use) NOTE: The quantities showninthe above table are Feforrad to the total capacity of the cooling system, Note that servicing capacity Is 9.5 ters (2.55 Gals.). 3. Start engine and bring to normal operating tempera- ture range, so thatopeningof thermostat will vent any air trapped in the system. 4. With cold engine, top-up coolant to the MAX level mark on the header tank. 5. Screw and tighten the header tank pressurized cap, NOTE: To Increase protection from -20°C (-4°F) to ~40°C (-40°F) without draining the sys- tem completely, replace about 4 Iiters (1.1 gals) of freezing mixture with the same ‘Quantity of the specified concentrated antl- freeze. Do not use ant/-rustadditives, which could be not compatible with the antl-freezeused In system. HEADER TANK ‘The header tank provides the following functions: - Supply the system with coolant in case the level decreases. - _ Expansion box forthe absorption of coolant changes of volume due tothe variations of tamperature during ‘engine operation. = Bleeding of air bubbles trapped in the system by means of two lines connectedio the highest points of the system. ‘A pressurized cap allows sealing of the header tank; ‘anyway, if excessive pressure builds-up in the tank, relief valve opens and discharges the excess pressure, Rolief valve setting: 100 kPa (14.5 p.si.) ‘The header tank is made of plastic. HEADER TANK 07-4COOLING SYSTEM 164 ‘sensor installed on the header tank controls a warning lamp on the instrument panel to alert when the level of ‘coolant in the tank is insufficient, MIN, COOLANT LEVEL WARNING Lae REMOVAL/INSTALLATION Drain the hydraulic system (refer to page 7-3). 2. Disconnect electric connector from the engine cool- ant level sensor. 3. Loosen clamps and disconnect all lines from the header tank. 4, Remove header tank. = PRESSURIZED CAP SEAL TEST Perform test using the seal test too! ‘Screw fitting to lower end of test tooi. 3. Installthe pressurized cap of header tank on tes\ too! fitting. 4, Manually actuate the test too! piston and pressurize the pressurized cap; read on the test tool gauge the Pressure value at which the cap relief valve opens. » TEST TOOL Fring PRESSURIZED CAP surized cap setting 100 kPa (14.5.2) HYDRAULIC SYSTEM PROOF TEST 1. Unscrew and remove pressurized cap from header tank. 2. Screw hydraulic system proof test too! and relevant fiting onto header tank filer. 3. Manually pressurize the system and check on proot test tool gauge that pressure remains to the pre- scribed value. if pressure decreases, check for leaks through the sleeves or radiator. 07-5Hydraulic system test pressure 107.9 kPa (15.6 p.s.l) WARNING: Due to safety reasons, never exceed the pressuté of 138 KPa (20 ps!) during tests described above, PUMP AND THERMOSTAT UNIT ‘The water pump is of the vane centrifugal type; the pump bodyis made ofa special aluminum alloy, andtheimpeller is made of castiron. The pumpis fixedto the engine block front side by means of nine screws. A gasket is installed between the engine block and the pump. “The pump is driven by the crankshaft through a "poly-V* type belt; continuous operation of the pump ensures a Continuous flow of coolant. The thermostat unit is located just above the pump body. The thermostat maintains the engine temperature within COOLING SYSTEM 184 the normal operating limits; the thermostat valve directs the coolant to the pump when the coolant temperature is below 87°C (18°F); when the coolant temperature ex- ceeds the above limit, the thermostat valve opens and directs the coolant to the radiator. ‘THERMOSTAT UNIT From cyincar heads maiotd The thermostat unit includes a coolant temperature sen- sor which supplies temperature signals to the coolant temperature gauge and coolant maximum temperature warning lamp on the instrument panel. weal coo.aet fas 35° | FepemtTune cause 1 Of — teat cootane TenrenaTune WARNING LAMP 07-6B COOLING SYSTEM 164 REMOVAL/INSTALLATION COOLANT. EXCHANGER LUNES (ONLY FOR VEHICLES EQUIPPED WITH WATER-OIL 1. Disconnect (-] lead from battery. HEAT EXCHANGER) 2, Drain hydraulic system (refer to page 7-3). 3. Disconnect pressure line from thermostat unit. 4. Disconnect the engine coolant temperature sensor connector (tor signals to the control unit), Disconnect ground cable. 6. Remove gauge and waming lamp temperature sen- sor (for signals to the instrument panel). 7. Disconnect the return line from the pump. 8. Remove the water pump and air conditioning com- pressor drive bett (refer fo Group 00). 9. Remove the engine timing belt (refer to Group 00). a 2.1 nibs ‘G0 Nem} 14810104 ftlbe (198 to 245 Nm) /coo.ayn rewerarune GAUGE AND MAK COOLANT ‘eipenatune wanna tine sEuson ENGINE COOLANT TEMPERATURE SENSOR GRouno CAME PRESSURE / UNE RETURN UNE 10. Disconnect coolanvoll exchanger lines (only for vehicles equipped with water-oil heat exchanger). 11. Using the torque reactor N. 1.820.051.000, remove the oil pump pulley. 12, Remove the coolant pump and air conditioning com- pressor belt tightener. 19, Remove water pump pulley. water PUMP PULLEY ~ / TaHTENER 14. Remove clamps from lines from cylinder heads to thermostat unit. 15. Remove the waterpump complete of thermostat unit. 16. Remove the gasket. 17. Reinstallthe parts by reversingthe orderof the above Steps; torque fixing parts to the prescribed values. LINES From CYLINDER HEADS. When theinstallation is completed, check belt tension (refer to Group 00); service the hy- Camy-out step A2 Tighten or replace at- fected clamps Az | PUMP AND THERMOSTAT UNIT CHECK Check pump and thermostat unit body for cracks or other defects () v © Qe © Carry-out step AS Replace detective items A3 | OIL CONTAMINATION CHECK + Check that the coolant has not contaminated the ‘engine oil;such faulty conditionis confirmed by traces ‘of a whitish substance in the engine oil Gy» © @) v Cy > Carry-oul step Ad Tighten the cylinder head Prescribed torque; screws to the should malfunction be recurring, replace the cylinder head gas- kets. ‘Aa | GAS PRESENCE CHECK INSIDE THE CIRCUIT - Using a special instrument applied to the expansion tank, check for absence of gas (Co + HC) inside the cooling circuit GF >» Tighten the cylinder ad screws to tho Prescribed torque; should maifunction be recurring, replace the cylinder head gas- kets 07-16 End of test ACOOLING SYSTEM 164 ENGINE OVERHEATING TESTB TEST STEPS RESULTS REMEDY B1_ | WARNING LAMP AND GAUGE CHECK + heck proper operation of coolant ternperature wam- ing lamp and gauge on instrument panel, and of ‘transmitters on engine (refer to WIRING DIAGRAMS > Carry-out step B2 AND ELECTRICAL DIAGNOSIS) > Repair or replace fected items B2_| COOLANT LEVEL CHECK - Check level of coolant > Carry-out step BS > Service coolant to Proper level; proof test the system B3 | ENGINE OIL LEVEL CHECK = Check level of engine oil Carry-out step B4 > Service engine oll to proper level {referto Group 00) B4 | BELT CHECK Check water pump drive belt for proper tension and > Carry-out step BS condition > Tighten belt to proper Q® | © | QO | QV value, or replace bett i damaged or exces- sively worn (refer to ‘Group 00) (Contd) 07-17BB COOLING SYSTEM TEST STEPS RESULTS: ENGINE OVERHEATING TESTB REMEDY 16g BS | ENGINE COOLANT ELECTRIC FAN CHECK = Check operation of engine coolant electric fan wiring system (refer to WIRING DIAGRAMS AND ELEC- TRICAL DIAGNOSIS) Q® Carry-out step BS. Replace electric fan of unserviceable parts of relevant wiring sys- tem B6 | THERMAL SWITCH CHECK ‘Check setting of cooling tan thermal switch {contacts > Carry-out step B7 close at 198°F; 92°C) switch 4 B7 | HOSE CHECK - Check coolant hoses for obstructions, visually inspect >» Carry-out step BS that sleeves are not squeezed or bent GY > Replace hoses BB | COOLANT FLOW CHECK ~ Check that coolant flows freely through the hoses by > Carry-out step BS manually pumping the hoses, and noting swashing in the header tank (Cont.d) —_—_—— CU 18COOLING SYSTEM tec = ENGINE OVERHEATING | TESTB ‘TEST STEPS RESULTS REMEDY 89 | RADIATOR CHECK + Checkradiatorfor absence of fouling orforeign matter Cary-out step B10 ®® Wash radiator with specific cleaners; make sure the engine radiator is of the ap- proved type B10 | WATER PUMP CHECK + Check water pump for condition and proper operation Cary-out step B11 hose between thermostat unit and radiator: verity the duct warms up gradually > Replace water pump and gasket 811 | THERMOSTAT UNIT CHECK Bring engine to normal temperature range, then touch Cany-out step 812 Replace thermostat unit and relevant gaskets B12 | THERMOSTAT UNIT SETTING CHECK Check thermostat unit for proper setting (refer to CHECKS AND INSPECTIONS - Thermostat urit) Q® | © |@Q@ Cary-out step B13 Replace thermostat unit and relevant gaskets 07-19 (Conta)5B COOLING SYSTEM 164 ENGINE OVERHEATING TEST STEPS = Check engine ignition timing RESULTS TESTB REMEDY B13 | ENGINE IGNITION TIMING CHECK Adjustengine ignition timing 07-20 End ottest B