GENERAL INFORMATION

The cooling system is a water-cooled pressurized, forced circulation type which offers the following
features:

The high-efficiency aluminium core has been adopted to thin and lighten the radiator.
The new-type radiator cap has been adopted and the cap position has been optimised to
improve air bleeding performance.
The shape of cooling fan shroud has been reviewed to improve cooling fan efficiency.
The air guide panel around the radiator has been added to improve cooling efficiency.
The cross-flow type of radiator has been adopted to abolish the metal bracket of radiator
installation area for light weighting.
The capacity of radiator condenser tank has been enlarged to prevent coolant from brimming
over.
The metal bracket of radiator condenser tank installation area has been abolished for light
weighting.

CONSTRUCTION DIAGRAM
SERVICE SPECIFICATIONS
Item Standard Limit
value
Valve opening pressure of radiator cap kPa 94 - 122 Minimum
84
Range of coolant antifreeze concentration of radiator % 30 - 60 -
Thermostat Valve opening temperature of 4M4, 6G7 (Vehicles for GCC) 76.5 ± 2 -
thermostat °C 4D5, 6G7 (Except vehicles for 82 ± 2 -
GCC)
6B3 82 ± 1.5 -
Full-opening temperature of 4M4, 6G7 (Vehicles for GCC) 90 -
thermostat °C 4D5, 6G7 (Except vehicles for 95 -
GCC), 6B3
Valve lift mm 4M4, 4D5, 6G7 10 or more -
6B3 9.0 or more -
LUBRICANT
Item Specified coolant Quantity
L
Engine coolant (including 0.65 L in the 4M4 DIA QUEEN SUPER LONG LIFE 8.5
radiator condenser tank) 4D5 COOLANT or equivalent 8.2
6G7 8.8
6B3 11.0
SEALANTS
Item Specified sealant Remark
Cylinder block drain plug <6G7> 3M Nut Locking Part No.4171 or exact Drying sealant
equivalent
Engine coolant temperature sensor ThreeBond 1324N, LOCTITE 262 or Anaerobic
equivalent sealant
Engine coolant temperature gauge ThreeBond 2310 or exact equivalent Anaerobic
unit sealant
SPECIAL TOOLS
Tool Number Name Use
MB991871 LLC changer Coolant refilling
MB992042 Water temperature sensor Engine coolant temperature sensor removal
wrench and installation
ENGINE COOLANT LEAK CHECK
1.
When pressure testing the cooling
warning system, slowly release cooling
system pressure to avoid getting
burned by hot coolant.

Be sure to completely clean

away any moisture from the
places checked.
When the tester is taken out,
caution be careful not to spill any
coolant.
Be careful when installing and
removing the tester and when
testing not to deform the filler
neck of the radiator.

Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa pressure,
and then check for leakage from the radiator hose or
connections.
2.If there is leakage, repair or replace the appropriate
part.
CONCENTRATION MEASUREMENT

If the concentration of the anti-freeze is below

30%, the anti-corrosion property will be
adversely affected. In addition, if the
caution concentration is above 60%, both the anti-
freezing and engine cooling properties will
decrease, affecting the engine adversely. For
these reasons, be sure to maintain the
concentration level within the specified range.
Measure the temperature and specific gravity of the engine
coolant to check the antifreeze concentration.

Standard value: 30 - 60% (allowable

concentration range)
Recommended antifreeze: DIA QUEEN SUPER
LONG LIFE COOLANT or equivalent
ENGINE COOLANT REPLACEMENT <4M4,
4D5, 6G7>
1.Remove the under skid plate and engine room under
cover front (Refer to GROUP 51 - Under Cover ).
2.
When removing the radiator cap, use
care to avoid contact with hot engine
coolant or steam. Place a shop towel
over the cap and turn the cap anti-
warning clockwise a little to let the pressure
escape through the vinyl tube. After
relieving the steam pressure, remove
the cap by slowly turning it anti-
clockwise.
Drain the engine coolant from the radiator, heater core and
engine after unplugging the radiator drain plug and
removing the radiator cap.
3.Drain the engine coolant in the water jacket by
unplugging the engine oil cooler assembly water drain
plug <4M4>.
4.Drain the engine coolant in the water jacket by
disconnect the engine oil cooler water feed hose of the
engine oil cooler <4D5>.
5.Drain the engine coolant in the water jacket by
unplugging the cylinder block drain plug <6G7>.
6.Remove the radiator condenser tank and drain the
engine coolant.
7.Drain the engine coolant then clean the path of the
engine coolant by injecting water into the radiator from
the radiator cap area.
8.Install the engine oil cooler water drain plug and new
gasket, and then tighten the engine oil cooler water
drain plug to the specified torque <4M4>.
Tightening torque: 31 ± 2 N·m
9.Connect the engine oil cooler water feed hose of the
engine oil cooler <4D5>.
10.Apply the designated sealant to the screw area of
the cylinder block drain plug, and then tighten to the
specified torque <6G7>.

Specified sealant: 3M Nut Locking Part

No.4171
Tightening torque: 39 ± 5 N·m
11.Securely tighten the radiator drain plug.
12.Reinstall the radiator condenser tank.
13.
Do not use alcohol or methanol
anti-freeze or any engine coolants
caution mixed with alcohol or methanol anti-
freeze. The use of an improper anti-
freeze can cause corrosion of the
aluminium components.
By referring to the section on engine coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60 %. Use
special tool LLC changer (MB991871) to refill the
engine coolant. A convenient mixture is a 50% water
and 50% antifreeze solution (freezing point: -31°C).

Recommended antifreeze: DIA QUEEN

SUPER LONG LIFE COOLANT or equivalent
Quantity (including 0.65 L in the radiator
condenser tank):

8.5 L <4M4>
8.2 L <4D5>
8.8 L <6G7>

For how to use special tool

note (MB991871), refer to its
manufacturer’s instructions.
14.Remove the special tool (MB991871), and then
reinstall the radiator cap.
15.Start the engine and let it warm up until the
thermostat opens.
16.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
17.Remove the radiator cap after the engine has
become cold, and pour in engine coolant up to the
brim. Reinstall the radiator cap.
18.
caution Do not overfill the radiator
condenser tank.
Add engine coolant to the radiator condenser tank
between the "FULL" and "LOW" mark if necessary.
19.Install the under skid plate and engine room under
cover front (Refer to GROUP 51 - Under Cover ).
ENGINE COOLANT REPLACEMENT <6B3>
1.Remove the under skid plate and engine room under
cover front (Refer to GROUP 51 - Under Cover ).
2.
When removing the radiator cap, use
care to avoid contact with hot engine
coolant or steam. Place a shop towel
over the cap and turn the cap anti-
warning clockwise a little to let the pressure
escape through the vinyl tube. After
relieving the steam pressure, remove
the cap by slowly turning it anti-
clockwise.
Drain the engine coolant from the radiator, heater core and
engine after unplugging the radiator drain plug and
removing the radiator cap.
3.Drain the engine coolant in the water jacket by
unplugging the cylinder block drain plug.
4.Remove the radiator condenser tank and drain the
engine coolant.
5.Drain the engine coolant then clean the path of the
engine coolant by injecting water into the radiator from
the radiator cap area.
6.Install the cylinder block drain plug and new gasket,
and then tighten the cylinder block drain plug to the
specified torque.

Tightening torque:

<Left bank> 29 ± 5 N·m

<Right bank> 140 ± 5 N·m
7.Securely tighten the radiator drain plug.
8.Reinstall the radiator condenser tank.
9.
Do not use alcohol or methanol
anti-freeze or any engine coolants
caution mixed with alcohol or methanol anti-
freeze. The use of an improper anti-
freeze can cause corrosion of the
aluminium components.
By referring to the section on engine coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60 %. Use
special tool LLC changer (MB991871) to refill the
engine coolant. A convenient mixture is a 50% water
and 50% antifreeze solution (freezing point: -31°C).

Recommended antifreeze: DIA QUEEN

SUPER LONG LIFE COOLANT or equivalent
Quantity (including 0.65 L in the radiator
condenser tank): 11.0 L

For how to use special tool

note (MB991871), refer to its
manufacturer’s instructions.
10.Remove the special tool (MB991871), and then
reinstall the radiator cap.
11.Start the engine and let it warm up until the
thermostat opens.
12.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
13.Remove the radiator cap after the engine has
become cold, and pour in engine coolant up to the
brim. Reinstall the radiator cap.
14.
caution Do not overfill the radiator
condenser tank.
Add engine coolant to the radiator condenser tank
between the "FULL" and "LOW" mark if necessary.
15.Install the under skid plate and engine room under
cover front (Refer to GROUP 51 - Under Cover ).
RADIATOR CAP VALVE OPENING PRESSURE
CHECK
1.
Be sure that the cap is clean before
note testing. Rust or other foreign
material on the cap seal will cause
an improper reading.
Use a cap adapter to attach the cap to the tester.
2.Increase the pressure until the indicator of the gauge
stops moving.

Limit: Minimum 84 kPa

Standard value: 94 - 122 kPa
3.Replace the radiator cap if the reading does not
remain at or above the limit.
REMOVAL AND INSTALLATION <4M4, 4D5,
6G7>
Pre-removal Operation
Under Skid Plate and Engine Room Under
Cover Front Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Engine Upper Cover Removal (Refer to
GROUP 11A - Engine Assembly ) <4M4>.
Engine Upper Cover Removal (Refer to
GROUP 11C - Engine Assembly ) <4D5>.
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner <4M4, 4D5>,
<6G7>).
Post-installation Operation
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner <4M4, 4D5>,
<6G7>).
Engine Upper Cover Installation (Refer to
GROUP 11A - Engine Assembly ) <4M4>.
Engine Upper Cover Installation (Refer to
GROUP 11C - Engine Assembly ) <4D5>.
Engine Coolant Refilling (Refer to ).
A/T Fluid Check (Refer to GROUP 23A - On-
vehicle Service, Essential Service ) <A/T>.
Under Skid Plate and Engine Room Under
Cover Front Installation (Refer to GROUP 51
- Under Cover ).
<4M4>
Removal
steps
1. Radiator
drain plug
2. Radiator
drain plug O-
ring
3. Radiator cap
<<A>> >>A<< 4. Radiator
upper hose
<<A>> >>A<< 5. Radiator
lower hose
6. Cooling fan
shroud cover
<<B>> 7. Transmission
fluid cooler
line hose
connection
<A/T>
<<B>> 8. Transmission
fluid cooler
line hose and
pipe
assembly
connection
<A/T>
9. Radiator
condenser
tank hose
10. Cooling fan
shroud
11. Radiator
assembly
12. Radiator
support lower
insulator
13. Air guide
panel
· Air cleaner
assembly
(Refer to
GROUP 15 -
Air Cleaner
14. Radiator
condenser
tank
assembly
<4D5>
Removal
steps
1. Radiator
drain plug
2. Radiator
drain plug O-
ring
3. Radiator cap
<<A>> >>A<< 4. Radiator
upper hose
<<A>> >>A<< 5. Radiator
lower hose
6. Cooling fan
shroud cover
<<B>> 7. Transmission
fluid cooler
line hose
connection
<A/T>
<<B>> 8. Transmission
fluid cooler
line hose and
pipe
assembly
connection
<A/T>
9. Radiator
condenser
tank hose
10. Cooling fan
shroud
11. Radiator
assembly
12. Radiator
support lower
insulator
13. Air guide
panel
· Air cleaner
assembly
(Refer to
GROUP 15 -
Air Cleaner
14. Radiator
condenser
tank
assembly

<6G7>
 Removal
steps
1. Radiator
drain plug
2. Radiator
drain plug O-
ring
3. Radiator cap
<<A>> >>A<< 4. Radiator
upper hose
5. Radiator
piping clip
<<A>> >>A<< 6. Radiator
lower hose
<<B>> 7. Transmission
fluid cooler
line hose
connection
<A/T>
8. Transmission
fluid cooler
line hose
clamp <A/T>
<<B>> 9. Transmission
fluid cooler
line hose
<A/T>
<<B>> 10. Transmission
fluid cooler
line hose
connection
<A/T>
11. Transmission
fluid oil
cooler return
tube <A/T>
12. Radiator
condenser
tank hose
13. Cooling fan
shroud cover
14. Cooling fan
shroud
15. Radiator
assembly
16. Radiator
support lower
insulator
17. Air guide
panel
 · Air cleaner
assembly
(Refer to
GROUP 15 -
Air Cleaner
18. Radiator
condenser
tank

REMOVAL SERVICE POINTS

<<A>> RADIATOR HOSE

DISCONNECTION

Make mating marks on the radiator hose and hose

clamp as shown to install them in the original position.
Then, remove them.

<<B>> TRANSMISSION FLUID

COOLER LINE HOSE
DISCONNECTION

Disconnect the hose from the radiator, and plug the hose
and nipple of the radiator to prevent the entry of dust and
dirt.

INSTALLATION SERVICE POINT

>>A<< RADIATOR HOSE

CONNECTION

1.Insert radiator hose as far as the projection of the

hose fitting or radiator.
2.Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
REMOVAL AND INSTALLATION <6B3>
Pre-removal Operation
Engine Coolant Draining (Refer to ).
Cooling Fan Shroud, Cooling Fan and
Cooling Fan Clutch Assembly Removal
(Refer to ).
Post-installation Operation
Cooling Fan Shroud, Cooling Fan and
Cooling Fan Clutch Assembly Installation
(Refer to ).
Engine Coolant Refilling (Refer to ).
A/T Fluid Check (Refer to GROUP 23A - On-
vehicle Service, Essential Service ).
 Removal
steps
1. Radiator
drain plug
2. Radiator
drain plug O-
ring
3. Radiator cap
<<A>> >>A<< 4. Radiator
upper hose
5. Radiator
piping clip
<<A>> >>A<< 6. Radiator
lower hose
<<B>> 7. Transmission
fluid cooler
line hose
connection
<<B>> 8. Transmission
fluid cooler
line hose
<<B>> 9. Transmission
fluid cooler
line hose
connection
10. Transmission
fluid oil
cooler return
tube
11. Radiator
condenser
tank hose
12. Radiator
assembly
13. Radiator
support lower
insulator
14. Air guide
panel
· Air cleaner
assembly
(Refer to
GROUP 15 -
Air Cleaner
15. Radiator
condenser
tank
REMOVAL SERVICE POINTS

<<A>> RADIATOR HOSE

DISCONNECTION

Make mating marks on the radiator hose and hose

clamp as shown to install them in the original position.
Then, remove them.

<<B>> TRANSMISSION FLUID

COOLER LINE HOSE
DISCONNECTION

Disconnect the hose from the radiator, and plug the hose
and nipple of the radiator to prevent the entry of dust and
dirt.

INSTALLATION SERVICE POINT

>>A<< RADIATOR HOSE

CONNECTION

1.Insert radiator hose as far as the projection of the

hose fitting or radiator.
2.Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
REMOVAL AND INSTALLATION <4M4>
Pre-removal Operation
Under Skid Plate and Engine Room Under
Cover Removal (Refer to GROUP 51 -
Under Cover ).
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner ).
Cooling Fan Shroud Removal (Refer to ).
Post-installation Operation
Cooling Fan Shroud Installation (Refer to ).
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner ).
Under Skid Plate and Engine Room Under
Cover Installation (Refer to GROUP 51 -
Under Cover ).

Removal steps
1. Cooling fan and
cooling fan clutch
assembly
2. Cooling fan
3. Cooling fan clutch
REMOVAL AND INSTALLATION <4D5>

Pre-removal Operation Post-installation Operation

Engine Upper Cover
Removal (Refer to GROUP
11C - Engine Assembly ).
Air Cleaner Assembly and Air
Cleaner Intake Duct Removal
(Refer to GROUP 15 - Air
Cleaner ).
Alternator and Power Steering Oil Pump Drive Belt Tension
Check (Refer to GROUP 11C - On-vehicle Service,
Alternator and Power Steering Oil Pump Drive Belt Tension
Check ).
Air Cleaner Assembly and Air Cleaner Intake Duct
Installation (Refer to GROUP 15 - Air Cleaner ).
Engine Upper Cover Installation (Refer to GROUP 11C -
Engine Assembly ).

Removal
steps
<<A>> · Alternator
and power
steering
oil pump
drive belt
(Refer to
GROUP
11C -
Crankshaft
Pulley ).
>>A<< 1. Cooling
fan and
cooling fan
clutch
assembly
2. Water
pump
pulley
3. Cooling
fan
4. Cooling
fan clutch

REMOVAL SERVICE POINT

<<A>> ALTERNATOR AND POWER
STEERING OIL PUMP DRIVE BELT
REMOVAL

Slightly loosen the cooling fan and cooling fan clutch

assembly mounting bolts before removal of the alternator
and power steering oil pump drive belt.

INSTALLATION SERVICE POINT

>>A<< COOLING FAN AND

COOLING FAN CLUTCH
ASSEMBLY INSTALLATION

Temporarily tighten the cooling fan and cooling fan clutch

assembly mounting bolts. Then, tighten them to the
specified torque after the installation of alternator and
power steering oil pump drive belt.
Tightening torque: 11 ± 1 N·m
REMOVAL AND INSTALLATION <6B3>
Pre-removal Operation
Under Skid Plate and Engine Room Under
Cover Front Removal (Refer to GROUP 51 -
Under Cover ).
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner ).
Post-installation Operation
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner ).
Under Skid Plate and Engine Room Under
Cover Front Installation (Refer to GROUP 51
- Under Cover ).
 Removal
steps
1. Cooling fan
shroud cover
2. Radiator
piping clip
connection
3. Transmission
fluid cooler
line hose
clamp
connection
4. Transmission
fluid oil
cooler return
tube
connection
5. Radiator
condenser
tank hose
· Alternator
and others
belt (Refer to
GROUP 11G
- Crankshaft
Pulley )
6. Cooling fan
shroud,
cooling fan
and cooling
fan clutch
assembly
7. Cooling fan
shroud
>>A<< 8. Cooling fan
and cooling
fan clutch
assembly
9. Cooling fan
pulley
10. Cooling fan
11. Cooling fan
clutch

INSTALLATION SERVICE POINT

>>A<< COOLING FAN AND
COOLING FAN CLUTCH
ASSEMBLY INSTALLATION

Temporarily tighten the mounting nuts of the cooling fan

clutch and cooling fan pulley, and install the alternator and
others belt. Then, tighten the mounting nuts to the specified
torque.
Tightening torque: 11 ± 1 N·m
REMOVAL AND INSTALLATION <6G7>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room
Under Cover Front Removal (Refer to
GROUP 51 - Under Cover ).
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner ).
Alternator & Others Belt Tension Check (Refer
to GROUP 11E - On-vehicle Service, Drive
Belt Tension Check ).
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner ).
Under Skid Plate and Engine Room Under
Cover Front Installation (Refer to GROUP 51 -
Under Cover ).

Removal
steps
1. Cooling
fan
shroud
cover
2. Cooling
fan
shroud
<<A>> >>B<< 3. Alternator
& others
belt
>>A<< 4. Cooling
fan and
cooling
fan clutch
assembly
5. Cooling
fan pulley
6. Cooling
fan
7. Cooling
fan clutch

REMOVAL SERVICE POINT

<<A>> ALTERNATOR & OTHERS

BELT REMOVAL
1.Before removing the alternator & others belt, slightly
loosen the mounting nuts of cooling fan clutch and cooling
fan pulley.
2.The following operations will be needed due to the
introduction of the serpentine drive system with the
alternator drive belt auto-tensioner.
(1) Securely insert the spindle handle or ratchet handle
with a 12.7 mm insertion angle into the jig hole of the
alternator drive belt auto-tensioner.
(2) Rotate the alternator drive belt auto-tensioner
clockwise and align hole A with hole B.
(3)
To reuse the
alternator & others
belt, draw an arrow
indicating the
caution rotating direction
(clockwise) on the
back of the
alternator & others
belt using chalk, etc.
Insert an L-shaped hexagon wrench, etc. into the hole
to fix and then remove the alternator & others belt.

INSTALLATION SERVICE POINTS

>>A<< COOLING FAN AND

COOLING FAN CLUTCH
ASSEMBLY INSTALLATION

Temporarily tighten the mounting nuts of the cooling fan

clutch and cooling fan pulley, and install the alternator &
others belt. Then, tighten the mounting nuts to the specified
torque.
Tightening torque: 11 ± 1 N·m

>>B<< ALTERNATOR & OTHERS

BELT INSTALLATION
1.

To reuse the alternator &

others belt, install it by
aligning the arrow mark on
the backside of belt marked
at the removal with the
rotating direction.
caution Check that the notches of the
notched pulley and the
notches of the alternator &
others belt are fit correctly.
Check that the alternator &
others belt is installed in the
centre of the flat surface of the
flat pulley.

Install the alternator & others belt to each pulley as

shown in the figure.

2.Securely insert the spindle handle or ratchet handle

with a 12.7 mm insertion angle into the jig hole of the
alternator drive belt auto-tensioner.
3.Turn the alternator drive belt auto-tensioner
clockwise slightly and remove the L-shaped hexagon
wrench to fix the alternator drive belt auto-tensioner.
4.Apply tension to the alternator & others belt while
slowly turning the spindle handle or ratchet handle to
rotate the alternator drive belt auto-tensioner anti-
clockwise.
INSPECTION

COOLING FAN CHECK

Check blades for damage and cracks.

Check for cracks and damage around bolt holes in
fan hub.
If any portion of fan is damaged or cracked, replace
cooling fan.

COOLING FAN CLUTCH CHECK

Check to ensure that fluid in cooling fan clutch is not

leaking at case joint and seals. If fluid quantity
decreases due to leakage, fan speed will decrease
and engine overheating might result.
When a fan attached to an engine is turned by hand, it
should give a sense of some resistance. If fan turns
lightly, it is faulty.
Check bimetal strip for damage.
REMOVAL AND INSTALLATION <4M4>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room Under
Cover Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner ).
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Installation (Refer to GROUP 51 -
Under Cover ).

Removal
steps
<<A>> >>B<< 1. Radiator
lower hose
connection
2. Thermostat
case cover
>>A<< 3. Thermostat

REMOVAL SERVICE POINT

<<A>> RADIATOR LOWER HOSE

DISCONNECTION

Make matching marks on the radiator lower hose and

the hose clamp. Disconnect the radiator lower hose.

INSTALLATION SERVICE POINTS

>>A<< THERMOSTAT
INSTALLATION

Make absolutely sure that no oil adheres to the

caution rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
 Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the rubber
ring.

>>B<< RADIATOR LOWER HOSE

CONNECTION

1.Insert the radiator lower hose as far as the projection

of the thermostat case cover.
2.Align the matching marks on the radiator lower hose
and hose clamp, and then connect the radiator lower
hose.
REMOVAL AND INSTALLATION <4D5>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine
Room Under Cover Removal
(Refer to GROUP 51 - Under
Cover ).
Engine Coolant Draining (Refer
to ).
Air Cleaner Assembly and Air
Cleaner Intake Duct Removal
(Refer to GROUP 15 - Air
Cleaner ).
A/C Compressor Drive Belt
Removal (Refer to GROUP
11C - Crankshaft Pulley ).
Alternator and Power Steering
Oil Pump Drive Belt Removal
(Refer to GROUP 11C -
Crankshaft Pulley ).
Alternator and Power Steering Oil Pump Drive Belt
Installation (Refer to GROUP 11C - Crankshaft Pulley ).
Alternator and Power Steering Oil Pump Drive Belt
Tension Check (Refer to GROUP 11C - On-vehicle
Service, Alternator and Power Steering Oil Pump Drive
Belt Tension Check ).
A/C Compressor Drive Belt Installation (Refer to GROUP
11C - Crankshaft Pulley ).
A/C Compressor Drive Belt Tension Check and
Adjustment (Refer to GROUP 11C - On-vehicle Service,
A/C Compressor Drive Belt Tension Check and
Adjustment ).
Air Cleaner Assembly and Air Cleaner Intake Duct
Installation (Refer to GROUP 15 - Air Cleaner ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under Cover
Installation (Refer to GROUP 51 - Under Cover ).

Removal
steps
<<A>> · Power
steering oil
pump
bracket A
<<B>> >>B<< 1. Radiator
lower hose
connection
2. Battery
wiring
harness
connection
3. Harness
bracket
4. Water
pump inlet
hose fitting
>>A<< 5. Thermostat

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL
PUMP BRACKET A REMOVAL

1.With the hose installed, remove the power steering oil

pump assembly from the power steering oil pump bracket
A (Refer to GROUP 11C - Engine Assembly ).
2.After removing the power steering oil pump assembly,
secure it with a cord in the location where the removal and
installation of the thermostat cannot be hindered.
3.Remove the power steering oil pump bracket A (Refer to
GROUP 37 - Power Steering Oil Pump Assembly ).

<<B>> RADIATOR LOWER HOSE

DISCONNECTION

Make matching marks on the radiator lower hose and

the hose clamp. Disconnect the radiator lower hose.

INSTALLATION SERVICE POINTS

>>A<< THERMOSTAT
INSTALLATION

Make absolutely sure that no oil adheres to the

caution rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
Install the thermostat as shown in the illustration. Be
careful not to fold or scratch the rubber ring.

>>B<< RADIATOR LOWER HOSE

CONNECTION

1.Insert the radiator lower hose as far as the projection

of the water pump inlet hose fitting.
2.Align the matching marks on the radiator lower hose
and hose clamp, and then connect the radiator lower
hose.
REMOVAL AND INSTALLATION <6G7>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room Under
Cover Front Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Air Cleaner Intake Duct Removal (Refer to
GROUP 15 - Air Cleaner ).
Air Cleaner Intake Duct Installation (Refer to
GROUP 15 - Air Cleaner ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Front Installation (Refer to GROUP 51
- Under Cover ).

Removal
steps
<<A>> >>B<< 1. Radiator
lower hose
connection
2. Cooling
water inlet
hose fitting
>>A<< 3. Thermostat

REMOVAL SERVICE POINT

<<A>> RADIATOR LOWER HOSE

DISCONNECTION

Make mating marks on the radiator lower hose and the

hose clamp. Disconnect the radiator lower hose.

INSTALLATION SERVICE POINTS

>>A<< THERMOSTAT
INSTALLATION

Make absolutely sure that no oil adheres to the

caution rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
 Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the rubber
ring.

>>B<< RADIATOR LOWER HOSE

CONNECTION

1.Insert the radiator lower hose as far as the projection

of the cooling water inlet hose fitting.
2.Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator lower
hose.
REMOVAL AND INSTALLATION <6B3>

Pre-removal Operation Post-installation Operation

Engine Coolant Draining (Refer to ). Engine Coolant Refilling (Refer to ).

Removal
steps
1. Control
wiring
harness and
battery
wiring
harness
combination
connector
connection
2. Battery
wiring
harness
connection
3. Harness
bracket
<<A>> >>B<< 4. Radiator
lower hose
connection
5. Cooling
water inlet
hose fitting
>>A<< 6. Thermostat

REMOVAL SERVICE POINT

<<A>> RADIATOR LOWER HOSE

DISCONNECTION

Make mating marks on the radiator hose and hose

clamp as shown to install them in the original position.
Then, remove them.
INSTALLATION SERVICE POINTS

>>A<< THERMOSTAT
INSTALLATION

Avoid adhesion of grease to the rubber ring of

caution the thermostat. If the rubber ring is damaged,
replace the thermostat.
Install the thermostat with care to avoid peeling or
damage to the rubber ring. When installing the
thermostat, face the jiggle valve of the thermostat
upward.

>>B<< RADIATOR LOWER HOSE

CONNECTION

1.Insert the radiator lower hose to the protrusion of the

cooling water inlet hose fitting.
2.Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator lower
hose.
INSPECTION

THERMOSTAT CHECK

1.Immerse the thermostat in water, and heat the water

while stirring. Check the thermostat valve opening
temperature.
Standard value:

76.5 ± 2°C <4M4, 6G7 (Vehicles for GCC)>

82 ± 2°C <4D5, 6G7 (Except vehicles for
GCC)>
82 ± 1.5°C <6B3>

2.Check that the amount of valve lift is at the standard

value when the water is at the full-opening temperature.
Measure the valve height when the
thermostat is fully closed, and use
note this measurement to compare the
valve height when the thermostat is
fully open.
Standard value:

Full-opening temperature:

90°C <4M4, 6G7 (Vehicles for GCC)>

95°C <4D5, 6G7 (Except vehicles for
GCC), 6B3>
Amount of valve lift:

10 mm or more <4M4, 4D5, 6G7>

9.0 mm or more <6B3>

REMOVAL AND INSTALLATION <4M4>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room
Under Cover Removal (Refer to
GROUP 51 - Under Cover ).
Engine Coolant Draining (Refer to ).
Cooling Fan Shroud Removal (Refer
to ).
Cooling Fan and Cooling Fan Clutch
Assembly Removal (Refer to ).
Cooling Fan and Cooling Fan Clutch Assembly
Installation (Refer to ).
Cooling Fan Shroud Installation (Refer to ).
Engine Coolant Refilling (Refer to ).
Drive Belt Tension Check and Adjustment (Refer to
GROUP 11A - On-Vehicle Service, Drive Belt
Tension Check and Adjustment ).
Under Skid Plate and Engine Room Under Cover
Installation (Refer to GROUP 51 - Under Cover ).

Removal
steps
<<A>> · Alternator
drive belt
(Refer to
GROUP
11A -
Crankshaft
Pulley ).
>>B<< 1. Cooling
fan clutch
plate
>>B<< 2. Cooling
fan pulley
3. Water
pump
>>A<< 4. Water
pump O-
ring

REMOVAL SERVICE POINT

<<A>> ALTERNATOR DRIVE BELT

REMOVAL

Slightly loosen the cooling fan clutch plate and cooling fan
pulley mounting bolts before removal of the alternator drive
belt.
INSTALLATION SERVICE POINTS

>>A<< WATER PUMP O-RING

INSTALLATION

caution Be careful not to contaminate the O-ring with

engine oil or grease.
Apply water around the O-ring before installing it.

>>B<< COOLING FAN

PULLEY/COOLING FAN CLUTCH
PLATE INSTALLATION

1.Install the cooling fan clutch plate and the cooling fan
pulley to the water pump. At this time, install the cooling fan
clutch plate with its stamp "544" facing toward the cooling
fan side.
2.Temporarily tighten the cooling fan clutch plate and
cooling fan pulley mounting bolts. Then, tighten them to the
specified torque after the installation of alternator drive belt.
Tightening torque: 24 ± 4 N·m
REMOVAL AND INSTALLATION <4D5>
Pre-removal Operation
Under Skid Plate and Engine Room Under
Cover Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Engine Upper Cover Removal (Refer to
GROUP 11C - Engine Assembly ).
Air Cleaner Assembly and Air Cleaner
Intake Duct Removal (Refer to GROUP 15 -
Air Cleaner ).
Crankshaft Balancer Shaft Drive Sprocket
Removal (Refer to GROUP 11C -
Crankshaft Oil Seal ).
Thermostat Removal (Refer to ).
Vacuum Pump Oil Return Pipe Removal
(Refer to GROUP 11C - Vacuum Pump ).
Post-installation Operation
Vacuum Pump Oil Return Pipe Installation
(Refer to GROUP 11C - Vacuum Pump ).
Thermostat Installation (Refer to ).
Crankshaft Balancer Shaft Drive Sprocket
Installation (Refer to GROUP 11C -
Crankshaft Oil Seal ).
Air Cleaner Assembly and Air Cleaner Intake
Duct Installation (Refer to GROUP 15 - Air
Cleaner ).
Engine Upper Cover Installation (Refer to
GROUP 11C - Engine Assembly ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Installation (Refer to GROUP 51 -
Under Cover ).
 Removal
steps
<<A>> · Power
Steering
Oil Pump
Bracket
B
1. Water
pump
inlet
fitting
plate
2. Water
pump
inlet
fitting
plate
gasket
3. Water
pump
4. Water
pump
gasket
>>A<< 5. Water
pump
water by-
pass
pipe O-
ring

REMOVAL SERVICE POINT

<<A>> POWER STEERING OIL

PUMP BRACKET B REMOVAL

1.With the hose installed, remove the power steering oil

pump assembly from the power steering oil pump bracket
A (Refer to GROUP 11C - Engine Assembly ).
2.After removing the power steering oil pump assembly,
secure it with a cord in the location where the removal and
installation of the water pump cannot be hindered.
3.Remove the power steering oil pump bracket B (Refer to
GROUP 37 - Power Steering Oil Pump Assembly ).
INSTALLATION SERVICE POINT

>>A<< WATER PUMP WATER BY-

PASS PIPE O-RING INSTALLATION

caution Be careful not to contaminate the O-ring with

engine oil or grease.
Apply water around the O-ring before installing it.
REMOVAL AND INSTALLATION <6B3>

Pre-removal Operation Post-installation Operation

Engine Coolant Draining (Refer to ). Timing Belt Installation (Refer to GROUP
Timing Belt Removal (Refer to GROUP 11G 11G - Timing Belt ).
- Timing Belt ). Engine Coolant Refilling (Refer to ).

Removal steps
1. Water pump
2. Water pump gasket
REMOVAL AND INSTALLATION <6G7>

Pre-removal Operation Post-installation Operation

Valve Timing Belt Removal (Refer to Thermostat Installation (Refer to ).
GROUP 11E - Timing Belt ). Valve Timing Belt Installation (Refer to
Thermostat Removal (Refer to ). GROUP 11E - Timing Belt ).

Removal
steps
<<A>> >>D<< 1. Radiator
upper hose
connection
2. Cooling
water line
hose
connection
3. Cooling
water line
hose
connection
4. Cooling
water outlet
fitting
bracket
5. Spark plug
cable clamp
6. Engine
coolant
temperature
gauge unit
connector
connection
7. Engine
coolant
temperature
sensor
connector
connection
>>C<< 8. Engine
coolant
temperature
gauge unit
<<B>> >>B<< 9. Engine
coolant
temperature
sensor
 10. Cooling
water outlet
hose fitting
>>A<< 11. O-ring
12. Cooling
water outlet
hose fitting
gasket
13. Water
pump,
thermostat
case and
water pump
by-pass
inlet fitting
assembly
14. Water
pump
gasket
>>A<< 15. O-ring
16. Thermostat
case and
water pump
by-pass
inlet fitting
assembly
17. Water
pump
assembly
18. Water
pump by-
pass inlet
fitting
gasket
19. Water
pump by-
pass inlet
fitting
20. Thermostat
case
21. Thermostat
case
gasket

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE
DISCONNECTION
Make mating marks on the radiator upper hose and
the hose clamp. Disconnect the radiator upper hose.

<<B>> ENGINE COOLANT

TEMPERATURE SENSOR
REMOVAL

Use special tool water temperature sensor wrench

(MB992042) to remove the engine coolant water
temperature sensor.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

Care must be taken not to permit engine

oil or other greases to adhere to the O-
caution ring.
When inserting the pipe, check to be sure
that there is no sand, dirt, etc. on its inner
surface.

Fit the O-ring to the groove in the cooling water outlet

pipe or water pump inlet pipe. Then lubricate the O-
ring and the inside of the cooling water outlet hose
fitting or water pump assembly with water, and then
insert the cooling water outlet pipe or water pump inlet
pipe to the cooling water outlet hose fitting or water
pump assembly.

>>B<< ENGINE COOLANT

TEMPERATURE SENSOR
INSTALLATION
 After the installation, until a sufficient period of
caution time (one hour or more) elapses, do not apply
the oil or water to the sealant application area or
start the engine.

Apply the sealant to the thread of engine coolant

temperature sensor. In the same manner as for
removal, using special tool water temperature sensor
wrench (MB992042), tighten to the specified torque.

Specified sealant: ThreeBond 1324N or

equivalent
Tightening torque: 29 ± 10 N·m

note Install the engine coolant temperature

sensor immediately after applying sealant.

>>C<< ENGINE COOLANT

TEMPERATURE GAUGE UNIT
INSTALLATION

After the installation, until a sufficient period of

caution time (one hour or more) elapses, do not apply
the oil or water to the sealant application area or
start the engine.
Apply the sealant to the thread of engine coolant
temperature gauge unit, and then tighten to the
specified torque.

Specified sealant: ThreeBond 2310

Tightening torque: 11 ± 1 N·m

Install the engine coolant temperature

note gauge unit immediately after applying
sealant.

>>D<< RADIATOR UPPER HOSE

CONNECTION
1.Insert the radiator upper hose as far as the projection
of the cooling water outlet hose fitting.
2.Align the mating marks on the radiator upper hose
and hose clamp, and then connect the radiator upper
hose.
REMOVAL AND INSTALLATION <6G7>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room Under
Cover Front and Rear Removal (Refer to
GROUP 51 - Under Cover ).
Engine Coolant Draining (Refer to ).
Inlet Manifold Removal (Refer to GROUP 15
- Inlet Muffler ).
Thermostat Removal (Refer to ).
Thermostat Installation (Refer to ).
Inlet Manifold Installation (Refer to GROUP
15 - Inlet Muffler ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Front and Rear Installation (Refer to
GROUP 51 - Under Cover ).

Removal
steps
<<A>> >>B<< 1. Radiator
upper hose
connection
2. Cooling
water line
hose
connection
3. Cooling
water line
hose
connection
4. Cooling
water
outlet hose
fitting and
thermostat
case
assembly
5. Thermostat
case
gasket
6. Water
pump by-
pass inlet
fitting
7. Water
pump by-
pass inlet
fitting
gasket
8. Throttle
body water
return hose
connection
 9. Cooling
water
outlet pipe
>>A<< 10. O-ring
11. Throttle
body water
feed hose
connection
12. Heater
piping
hose
connection
13. Water
pump inlet
pipe
>>A<< 14. O-ring
15. Heater
piping
hose
connection
16. Cylinder
head water
by-pass
pipe
17. Cylinder
head water
by-pass
pipe
gasket

REMOVAL SERVICE POINT

<<A>> RADIATOR UPPER HOSE

DISCONNECTION

Make mating marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

 Care must be taken not to permit engine
oil or other greases to adhere to the O-
caution ring.
When inserting the pipe, check to be sure
that there is no sand, dirt, etc. on its inner
surface.

Fit the O-ring to the groove in the water pump inlet pipe
or cooling water outlet pipe. Then lubricate the O-ring
and the inside of the water pump assembly, cylinder
head water by-pass pipe or cooling water outlet fitting
with engine coolant. Then insert the water pump inlet
pipe or cooling water outlet pipe to the water pump
assembly, cylinder head water by-pass pipe or cooling
water outlet fitting with engine coolant.

>>B<< RADIATOR UPPER HOSE

CONNECTION

1.Insert the radiator upper hose as far as the projection

of the cooling water outlet hose fitting.
2.Align the mating marks on the radiator upper hose
and hose clamp, and then connect the radiator upper
hose.
REMOVAL AND INSTALLATION <6B3>

Pre-removal Operation Post-installation Operation

Engine Upper Cover Assembly and Engine
Cover Bracket Removal (Refer to GROUP
11G - Engine Assembly ).
Air Cleaner to Throttle Body Duct Removal
(Refer to GROUP 15 - Air Cleaner ).
Thermostat Removal (Refer to ).
Thermostat Installation (Refer to ).
Air Cleaner to Throttle Body Duct Installation
(Refer to GROUP 15 - Air Cleaner ).
Engine Upper Cover Assembly and Engine
Cover Bracket Installation (Refer to GROUP
11G - Engine Assembly ).

Removal
steps
<<A>> >>D<< 1. Radiator
upper hose
connection
2. Engine
coolant
temperature
sensor
connector
connection
<<B>> >>C<< 3. Engine
coolant
temperature
sensor
4. Engine
coolant
temperature
gauge unit
connector
connection
>>B<< 5. Engine
coolant
temperature
gauge unit
6. Water hose
connection
7. Water hose
connection
8. Cooling
water outlet
hose fitting
9. Gasket
10. Harness
bracket
 11. Rocker
cover
breather &
water hose
connection
12. Cooling
water outlet
pipe
>>A<< 13. O-ring
14. Cooling
water line
hose
15. Thermostat
case
bracket
· Air intake
plenum
(Refer to
GROUP 15
- Air Intake
Plenum )
16. Thermostat
case
17. Gasket
· Inlet
manifold
(Refer to
GROUP 15
- Inlet
Manifold )
18. Heater
hose
connection
19. Heater
hose
connection
20. Water
pump inlet
pipe
>>A<< 21. O-ring
· Front deck
panel
(Refer to
GROUP 42
- Loose
Panel )
 · Engine oil
control
valve (Refer
to GROUP
11G - Oil
Control
Valve )
· Heater
water pipe
assembly A
(Refer to
GROUP
55A -
Heater
Hose )
22. Cylinder
head water
by-pass
pipe
23. Gasket
24. Gasket
· Timing belt
rear cover
(Refer to
GROUP
11G -
Camshaft
Oil Seal )
25. Water hose
26. Cooling
water outlet
hose fitting
RH
27. Gasket
28. Water hose
29. Cooling
water outlet
hose fitting
LH
30. Gasket

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE

DISCONNECTION
 Make mating marks on the radiator hose and hose
clamp as shown to install them in the original position.
Then, remove them.

<<B>> ENGINE COOLANT

TEMPERATURE SENSOR
REMOVAL

Use special tool engine coolant temperature sensor

wrench (MB992042) to remove the engine coolant
temperature sensor.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

caution Do not allow engine oil or other grease to

adhere to the O-ring
Fit the O-ring in the water pipe groove, wet the O-ring
circumference or the pipe mounting area inner wall,
and then insert the O-ring.

>>B<< ENGINE COOLANT

TEMPERATURE GAUGE UNIT
INSTALLATION

After the installation, until a sufficient period of

caution time (one hour or more) elapses, do not apply
the oil or water to the sealant application area or
start the engine.
Apply the specified sealant to the thread of the engine
coolant temperature gauge unit, and then tighten it to
the specified torque.

Specified sealant: ThreeBond 2310

Tightening torque: 10.5 ± 0.5 N·m

Install the engine coolant temperature

note gauge unit immediately after applying
sealant.
>>C<< ENGINE COOLANT
TEMPERATURE SENSOR
INSTALLATION

1.Apply the sealant to the thread of engine coolant

temperature sensor.
Specified sealant: ThreeBond 1324N or
equivalent
Install the engine coolant
note temperature sensor immediately
after applying sealant.
2.
After the installation, until a
sufficient period of time (one hour
caution or more) elapses, do not apply the
oil or water to the sealant
application area or start the engine.
In the same manner as for removal, using special tool
water temperature sensor wrench (MB992042), tighten
to the specified torque.
Tightening torque: 30 ± 9 N·m

>>D<< RADIATOR UPPER HOSE

CONNECTION

1.Insert radiator upper hose as far as the projection of

the cooling water outlet hose fitting.
2.Align the mating marks on the radiator upper hose
and hose clamp, and then connect the radiator upper
hose.
REMOVAL AND INSTALLATION <4M4>

Pre-removal Operation Post-installation Operation

Engine Upper Cover Removal (Refer to
GROUP 11A - Engine Assembly ).
Under Skid Plate and Engine Room Under
Cover Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Installation (Refer to GROUP 51 -
Under Cover ).
Engine Upper Cover Installation (Refer to
GROUP 11A - Engine Assembly ).

Removal
steps
<<A>> >>D<< 1. Radiator
upper hose
connection
2. Cooling
water line
hose
3. Engine
coolant
temperature
gauge unit
connector
>>C<< 4. Engine
coolant
temperature
gauge unit
5. Engine
coolant
temperature
sensor
connector
connector
<<B>> >>B<< 6. Engine
coolant
temperature
sensor
7. Cooling
water outlet
hose fitting
8. Cooling
water outlet
hose fitting
gasket
 9. Battery
wiring
harness
connection
10. Cooling
water line
hose
11. Cooling
water outlet
pipe
>>A<< 12. O-ring
13. Emission
control hose
connection
14. Brake
booster
vacuum hose
connection
15. Vacuum
pump pipe
16. Turbocharger
water return
pipe
17. Turbocharger
water return
pipe gasket
18. Turbocharger
water feed
pipe
19. Turbocharger
water feed
pipe gasket
20. Cooling
water line
hose
21. Turbocharger
oil feed pipe
connection
22. Cooling
water inlet
pipe
>>A<< 23. O-ring
 24. Heater
piping hose
connection
<Vehicles
with heater>
or by-pass
hose
connection
<Vehicles
without
heater>
· Turbocharger
assembly
and exhaust
manifold
assembly
(Refer to
GROUP 15 -
Exhaust
Manifold and
Turbocharger
)
25. Engine
heater water
by-pass pipe
>>A<< 26. O-ring
27. Thermostat
water by-
pass pipe
>>A<< 28. O-ring
· Thermostat
(Refer to
· Alternator
adjusting
brace
assembly
(Refer to
GROUP 16 -
Alternator
Assembly
29. Harness
bracket
30. Thermostat
case
>>A<< 31. O-ring

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE
DISCONNECTION

Make matching marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.

<<B>> ENGINE COOLANT

TEMPERATURE SENSOR
REMOVAL

Use special tool water temperature sensor wrench

(MB992042) to remove the engine coolant
temperature sensor.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION

caution Care must be taken not to permit engine oil or

other greases to adhere to the O-ring.
Insert the O-ring to pipe, and coat the outer circumference
of the O-ring with water.

>>B<< ENGINE COOLANT

TEMPERATURE SENSOR
INSTALLATION

1.Apply the sealant to the thread of engine coolant

temperature sensor.
Specified sealant: ThreeBond 1324N or
equivalent
Install the engine coolant
note temperature sensor immediately
after applying sealant.
 2.
After the installation, until a
sufficient period of time (one hour
caution or more) elapses, do not apply the
oil or water to the sealant
application area or start the engine.
In the same manner as for removal, using special tool
water temperature sensor wrench (MB992042), tighten
to the specified torque.
Tightening torque: 30 ± 9 N·m

>>C<< ENGINE COOLANT

TEMPERATURE GAUGE UNIT
INSTALLATION

After the installation, until a sufficient period of

caution time (one hour or more) elapses, do not apply
the oil or water to the sealant application area or
start the engine.
Apply the sealant to the thread of engine coolant
temperature gauge unit, and then tighten to the
specified torque.

Specified sealant: ThreeBond 2310

Tightening torque: 10.5 ± 0.5 N·m

Install the engine coolant temperature

note gauge unit immediately after applying
sealant.

>>D<< RADIATOR UPPER HOSE

CONNECTION

1.Insert the radiator upper hose as far as the projection

of the cooling water outlet hose fitting.
2.Align the matching marks on the radiator upper hose
and hose clamp, and then connect the radiator upper
hose.
REMOVAL AND INSTALLATION <4D5>

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room Under
Cover Removal (Refer to GROUP 51 -
Under Cover ).
Engine Coolant Draining (Refer to ).
Engine Upper Cover Removal (Refer to
GROUP 11C - Engine Assembly ).
Air Cleaner Assembly and Air Cleaner
Intake Duct Removal (Refer to GROUP 15 -
Air Cleaner ).
Air Cleaner Assembly and Air Cleaner Intake
Duct Installation (Refer to GROUP 15 - Air
Cleaner ).
Engine Upper Cover Installation (Refer to
GROUP 11C - Engine Assembly ).
Engine Coolant Refilling (Refer to ).
Under Skid Plate and Engine Room Under
Cover Installation (Refer to GROUP 51 -
Under Cover ).

<Except vehicles with high

power engine>
Removal
steps
· Engine oil
refilling
(Refer to
GROUP 12 -
On-vehicle
Service,
Engine Oil
Replacement
) <Installation
only>.
· Exhaust
manifold
(Refer to
GROUP 15 -
Exhaust
Manifold and
Turbocharger
)
<<A>> · Power
steering oil
pump
bracket A
· Vacuum
pump oil
return pipe
(Refer to
GROUP 11C
- Vacuum
Pump )
 1. Turbocharger
water return
hose
2. Turbocharger
water feed
pipe
3. Turbocharger
water feed
pipe gasket
4. Turbocharger
water feed
hose
5. Turbocharger
water return
pipe
6. Turbocharger
water return
pipe gasket
7. Engine oil
cooler water
return hose
8. Engine oil
cooler water
feed hose
9. Engine oil
cooler water
inlet pipe
10. Cooling
water line
joint
11. Heater
piping hose
connection
<Vehicles
with heater>
or by-pass
hose
connection
<Vehicles
without
heater>
12. Water pump
water by-
pass pipe
>>E<< 13. O-ring
Removal
steps
 · Timing belt
under cover
(Refer to
GROUP 11C
- Camshaft
and Valve
Stem Seal
· Windshield
wiper link
and
windshield
wiper motor
(Refer to
GROUP 51 -
Windshield
Wiper )
· Fuel injection
pipe, fuel
supply pump
pipe (Refer
to GROUP
13C -
Common
Rail and
Supply Pump
)
· Glow plug
connecting
plate (Refer
to GROUP
16 - Glow
Plug )
14. Turbocharger
water feed
fitting to pipe
hose
15. Turbocharger
water feed
hose to hose
pipe
>>D<< 16. Front case
stiffener
<<B>> >>C<< 17. Radiator
upper hose
connection
18. Engine
coolant
temperature
gauge unit
connector
connection
 >>B<< 19. Engine
coolant
temperature
gauge unit
20. Engine
coolant
temperature
sensor
connector
connection
<<C>> >>A<< 21. Engine
coolant
temperature
sensor
22. Cooling
water outlet
hose fitting
23. Cooling
water outlet
hose fitting
gasket
<Vehicles with high power
engine>
Removal
steps
· Engine oil
refilling
(Refer to
GROUP 12 -
On-vehicle
Service,
Engine Oil
Replacement
) <Installation
only>.
· Exhaust
manifold
(Refer to
GROUP 15 -
Exhaust
Manifold and
Turbocharger
)
<<A>> · Power
steering oil
pump
bracket A
 · Vacuum
pump oil
return pipe
(Refer to
GROUP 11C
- Vacuum
Pump )
1. Engine oil
cooler water
return hose
connection
2. Engine oil
cooler water
feed hose
3. Heater
piping hose
connection
4. Water pump
water by-
pass pipe
>>E<< 5. O-ring
6. Engine oil
cooler water
feed hose
7. Engine oil
cooler water
inlet pipe
8. Cooling
water line
joint
Removal
steps
· Timing belt
under cover
(Refer to
GROUP
11C -
Camshaft
and Valve
Stem Seal
 · Fuel
injection
pipe, fuel
supply
pump pipe
(Refer to
GROUP
13C -
Common
Rail and
Supply
Pump )
· Glow plug
connecting
plate (Refer
to GROUP
16 - Glow
Plug )
9. Water hose
10. Vacuum
hose
connection
11. Vacuum
pipe
assembly
12. Water hose
>>D<< 13. Front case
stiffener
<<B>> >>C<< 14. Radiator
upper hose
connection
15. Engine
coolant
temperature
gauge unit
connector
connection
>>B<< 16. Engine
coolant
temperature
gauge unit
17. Engine
coolant
temperature
sensor
connector
connection
<<C>> >>A<< 18. Engine
coolant
temperature
sensor
 19. Cooling
water outlet
hose fitting
20. Cooling
water outlet
hose fitting
gasket

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL

PUMP BRACKET A REMOVAL

1.With the hose installed, remove the power steering oil

pump assembly from the power steering oil pump bracket
A (Refer to GROUP 11C - Engine Assembly ).
2.After removing the power steering oil pump assembly,
secure it with a cord in the location where the removal and
installation of the thermostat cannot be hindered.
3.Remove the power steering oil pump bracket A (Refer to
GROUP 37 - Power Steering Oil Pump Assembly ).

<<B>> RADIATOR UPPER HOSE

DISCONNECTION

Make matching marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.

<<C>> ENGINE COOLANT

TEMPERATURE SENSOR
REMOVAL

Use special tool water temperature sensor wrench

(MB992042) to remove the engine coolant
temperature sensor.

INSTALLATION SERVICE POINTS

>>A<< ENGINE COOLANT
TEMPERATURE SENSOR
INSTALLATION

1.Apply the sealant to the thread of engine coolant

temperature sensor.
Specified sealant: ThreeBond 1324N or
equivalent
Install the engine coolant
note temperature sensor immediately
after applying sealant.
2.
After the installation, until a
sufficient period of time (one hour
caution or more) elapses, do not apply the
oil or water to the sealant
application area or start the engine.
In the same manner as for removal, using special tool
water temperature sensor wrench (MB992042), tighten
to the specified torque.
Tightening torque: 30 ± 9 N·m

>>B<< ENGINE COOLANT

TEMPERATURE GAUGE UNIT
INSTALLATION

After the installation, until a sufficient period of

caution time (one hour or more) elapses, do not apply
the oil or water to the sealant application area or
start the engine.
Apply the specified sealant to the thread of the engine
coolant temperature gauge unit, and then tighten it to
the specified torque.

Specified sealant: ThreeBond 2310

Tightening torque: 11 ± 1 N·m

Install the engine coolant temperature

note gauge unit immediately after applying
sealant.
>>C<< RADIATOR UPPER HOSE
CONNECTION
1.Insert the radiator upper hose as far as the projection
of the cooling water outlet hose fitting.
2.Align the matching marks on the radiator upper hose
and hose clamp, and then connect the radiator upper
hose.

>>D<< FRONT CASE STIFFENER

INSTALLATION

1.Temporarily tighten the front case stiffener with bolts.

2.Tighten the bolt A located at the front case side to
the specified torque.
Tightening torque: 50 ± 5 N·m
3.Next, tighten the bolt B located at the cylinder block
assembly side to the specified torque.
Tightening torque: 50 ± 5 N·m

>>E<< O-RING INSTALLATION

caution Be careful not to contaminate the O-ring with

engine oil or grease.
Apply water around the O-ring before installing it.
INSPECTION

WATER PIPE AND HOSE CHECK

Check the water pipe and hose for cracks, damage and
clogs. Replace them if necessary.
WATER PUMP ENGINE COOLANT LEAK
CHECK
Even when the water pump is normal, a residue of the
engine coolant draining may be found on the drain hole, the
vapour hole and the installation surface of the water pump.
If a residue of the engine coolant draining is found, check
the water pump leakage by following method.
1.Remove the accessory mount assembly and timing belt
upper cover (Refer to GROUP 11E - Timing Belt ) <6G7>,
(Refer to GROUP 11G - Timing Belt ) <6B3>.
2.Wipe off the residue of the engine coolant draining on the
water pump.
3.
warning Make sure that the engine coolant is
cold when removing the radiator cap.
Remove the radiator cap.
4.
caution Do not pressures 100 kPa or more.
Install the radiator tester and pressures at 100 kPa.
5.Hold the pressurized state for 20 minutes, and check
that the engine coolant leakage from the drain hole, the
vapour hole or the installation surface of the water
pump.
6.Remove the radiator tester, and install the radiator
cap.
7.Install the accessory mount assembly and timing belt
upper cover (Refer to GROUP 11E - Timing Belt )
<6G7>, (Refer to GROUP 11G - Timing Belt ) <6B3>.
8.Warm up the engine, let it idle for 20 minutes and
stop it.
9.Remove the accessory mount assembly and timing
belt upper cover (Refer to GROUP 11E - Timing Belt )
<6G7>, (Refer to GROUP 11G - Timing Belt ) <6B3>.
10.Check that the engine coolant leakage from the
drain hole, the vapour hole or the installation surface of
the water pump.
11.If the engine coolant leakage is found in step 5 or
10, replace the water pump (Refer to <4M4>, <4D5>,
<6G7>, <6B3>).
12.Install the accessory mount assembly and timing
belt upper cover (Refer to GROUP 11E - Timing Belt )
<6G7>, (Refer to GROUP 11G - Timing Belt ) <6B3>.
GENERAL INFORMATION

The cooling system is a water-cooled pressurized, forced circulation type which offers the following
features:

The high-efficiency aluminium core has been adopted to thin and lighten the radiator.
The new-type radiator cap has been adopted and the cap position has been optimised to
improve air bleeding performance.
The shape of cooling fan shroud has been reviewed to improve cooling fan efficiency.
The air guide panel around the radiator has been added to improve cooling efficiency.
The cross-flow type of radiator has been adopted to abolish the metal bracket of radiator
installation area for light weighting.
The capacity of radiator condenser tank has been enlarged to prevent coolant from brimming
over.
The metal bracket of radiator condenser tank installation area has been abolished for light
weighting.

SPECIFICATIONS

Item 4M4 4D5

Cooling method Intake control method
Cooling fan Type With engine driven-type thermo clutch
Water pump Type Centrifugal impeller
Drive method Alternator drive Alternator and power steering
belt oil pump drive belt
Thermostat Type Wax pellet with Wax pellet
jiggle valve
Valve open temperature °C 76.5 ± 2 82 ± 2
Radiator Type Pressurized corrugate type
Core size (width × height × 632.2 × 524.2 × 632.2 × 524.2 × 27
thickness) mm 16
Performance kJ/h 244,300 321,000
Built-in A/T fluid Type Double tube type
cooler <A/T> Performance kJ/h 6,800
Engine coolant Specified coolant DIA QUEEN SUPER LONG LIFE COOLANT
or equivalent
Quantity L (including 0.65 L in the 8.5 8.2
radiator condenser tank)
Item 6G7
Except GCC GCC
Cooling method Intake control method
Cooling fan Type With engine driven-type thermo clutch
Water pump Type Centrifugal impeller
 Drive method Valve timing belt
Thermostat Type Wax pellet with jiggle valve
Valve open temperature °C 82 ± 2 76.5 ± 2
Radiator Type Pressurized corrugate type
Core size (width × height × thickness) 632.2 × 524.2 × 16
mm
Performance kJ/h 196,700
Built-in A/T oil Type Double tube type
cooler <A/T> Performance kJ/h 6,800
Engine coolant Specified coolant DIA QUEEN SUPER LONG LIFE
COOLANT or equivalent
Quantity (including radiator 8.8
condenser tank 0.65 L) L

CONSTRUCTION DIAGRAM
WATER PASSAGE
<4M4>
<4D5-Except Vehicles for Australia and New Zealand>
<4D5-Vehicles for Australia and New Zealand>
<6G7>