MAN-00162

Repair Manual Engine Cooling Nov 2011/ Rev 2

ENGINE COOLING

CONTENTS

Description and Operation .............................................................1

Electric Fan Logic ............................................................................2

Case 1: AC- Off ................................................................................. 2
Case 2: AC- On & AC Pressure < 18Bar (No Signal from MPS) ...... 2
Case 3: AC- On & AC Pressure > 18Bar (Signal from MPS) ............ 3

Component Location Index............................................................. 4

Service Tips and Precautions......................................................... 5

Precautions with Degassing tank ....................................................... 5

In Car Repairs ...................................................................................6

Engine Coolant Replacement/Filling and Bleeding Procedure: ......... 6
Cooling System Draining ................................................................... 7
Water pump leakage test .................................................................. 7
Cooling system leakage test .............................................................. 7

Radiator......................................................................................... 8
Removal ............................................................................................ 8
Inspection ......................................................................................... 10
Installation ........................................................................................ 10

Radiator Support Cross Bar / Front End Module .................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 13

Degassing Tank.......................................................................... 13
Removal .......................................................................................... 13
Inspection......................................................................................... 14
Installation ........................................................................................ 14

Assembly Hose Radiator to Degas Tank ................................ 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15

Assembly Hose Engine to Degassing Tank .............................16

Removal ........................................................................................... 16
Installation ........................................................................................ 16

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Degas Tank to Engine .................................... 17

Removal ........................................................................................... 17
Installation ........................................................................................ 17

Assembly Hose Radiator Bypass ............................................. 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18

Assembly Hose Radiator Inlet .................................................. 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19

Assembly Hose Radiator Outlet ............................................... 20

Removal ........................................................................................... 20
Installation ........................................................................................ 20

EGR Hose (EGR Cooler to Coolant Outlet Hose) .................... 21

Removal ............................................................................................ 21
Installation ........................................................................................ 21

EGR Hose (Engine to EGR Cooler) ......................................... 22

Removal ........................................................................................... 22
Installation ........................................................................................ 22

Heater Hoses (Inlet and Outlet) ................................................ 22

Removal .......................................................................................... 22
Installation ........................................................................................ 22

Oil Cooler Hoses ........................................................................ 23

Removal .......................................................................................... 23
Installation ........................................................................................ 23

Coolant Outlet Joint Hose ......................................................... 24

Removal .......................................................................................... 24
Installation ........................................................................................ 24

Thermostat ................................................................................ 24
Removal .......................................................................................... 24
Installation ........................................................................................ 25

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Water Pump ...............................................................................26

Removal ........................................................................................... 26
Installation ........................................................................................ 27

Engine Oil Cooler .......................................................................28

Removal ........................................................................................... 28
Installation ........................................................................................ 28

Coolant Temperature Sensor .................................................... 29

Removal ........................................................................................... 29
Installation ........................................................................................ 29

Assembly Electric /Cooling Fan and Shroud with Flaps ........ 30

Removal ........................................................................................... 30
Installation ........................................................................................ 31

Cooling Fan Resistor ................................................................32

Removal ........................................................................................... 32
Installation ........................................................................................ 32

Cooling Fan Shroud with Flaps ................................................33

Removal ........................................................................................... 33
Installation ........................................................................................ 33

Diagnosis and Testing ...................................................................33

Inspection and Verification ............................................................... 33
Troubleshooting Chart ...................................................................... 34
Component Inspection Table ........................................................... 36

Mahindra Special Tools (MST) ......................................................36

Technical Specification ................................................................37

Torque Specification .....................................................................38

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Engine Cooling
Description and Operation
Vent Hose From radiator

Thermostat

RADIATOR ASSY.

Engine water outlet

ELECTRIC FAN De-gassing tank
Engine water Inlet

Thermostat Bypass hose

Vent Hose From Engine

ENGINE

EGR
Oil Cooler
Make up Hose

Water Pump Heater Core

Above Schematic gives the coolant flow circuit with the components. The coolant flow is controlled by the
thermostat. In addition to the Cylinder head and block, the coolant also circulates through Oil cooler, HVAC
heater core and EGR Cooler. Cooling system is designed to dissipate the excess heat energy liberated from
engine combustion. It maintains the engine temperature in specified range to achieve the maximum
combustion efficiency at all engine speeds, in different operating conditions.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-1
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Electric Fan Logic

Case 1: AC- Off

Case 1: AC-Off

Modulation is based on Coolant Temperature

Low High
Fan off speed speed
94°C 98°C 101°C 105°C

Temperature
Increasing

Low High
Fan off speed speed
94°C 98°C 101°C

Temperature
Decreasing

Case 2: AC- On & AC Pressure < 18Bar (No Signal from MPS - Middle Pressure
Switch)

Case 2: AC-On & AC Pressure < 18Bar (No Signal from MPS)

Modulation is based on Coolant Temperature

Low High
Fan off speed speed
94°C 98°C 101°C 105°C

Temperature
Increasing

Low High
Fan off speed speed
94°C 98°C 101°C

Temperature
Decreasing

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-2 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Case 3: AC- On & AC Pressure > 18Bar (Signal from MPS - Middle Pressure
Switch)

Case 3: AC-On & AC Pressure > 18Bar (Signal from MPS)

Modulation is based on Coolant Temperature

Low Low High

Any speed speed speed
Temp°C 94°C 98°C 105°C

Temperature
Increasing

Low Low High

Any speed speed speed
Temp°C 94°C 98°C 105/101°C

Temperature
Decreasing

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-3
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Component Location Index

A J

M B
K
D
L E

C C

J G D
B F

I
A

I E M
H G
H
K
F L

A. Degassing Tank H. Radiator

B. Degas Hose from Degas Tank I. CRFM Seal BOTTOM
C. Degas Hose from Engine J. CRFM Seal TOP
D. Electric Fan and Shroud K. CRFM Seal RH
E. Radiator Outlet Hose L. Radiator Inlet Hose
F. CRFM Seal LH M. Degas Hose from Radiator
G. Radiator Bypass Hose

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-4 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Service Tips and Precautions
Observe the following precautions when disassem-
bling or servicing the cooling system and its compo-
nents.
• Ensure that the work place is a dust free envi-
ronment.
• Do not remove the radiator drain cock or the
Engine coolant plate drain with the engine in hot
condition.
• If the coolant is not contaminated then collect
the coolant in a clean container so that it can be
reused. Replace coolant as per recommenda-
tion.
• Always ensure that Spring band Clamp
Position is with respect to hose as per paint
marking.
• Use cloth to clean the parts, common shop rags
can leave lint that might interfere with the opera-
tion of the cooling system parts.
• Avoid twisting or stressing of the engine cooling
hoses.
• Always maintain coolant level to the recom-
mended level.
DANGER
Do not commence repair operations of the
cooling system until the engine is switched
OFF and cooled down considerably. The pres-
sure within the system is extremely high which
will cause personal injury.

A CAUTION
Eye protection must be worn while working
near the cooling system, failure to follow this
may cause personal injury.

DANGER
Never open the degas tank pressure cap when
coolant is hot. The pressure within the system
is extremely high, failure to follow this instruc-
tion will cause personal injury.

A. White Marking Engine End Precautions with Degassing tank

1. Do not open pressure cap when coolant in
heated condition.
2. Coolant level shall be between Max line to Min
line.
3. Ensure Proper tightening of the Pressure cap.
B
4. Ensure 70:30 (water + coolant) will be filled.

B. Yellow Marking Radiator End

• Before installing or servicing the cooling
system, clean the outer surface of the parts.
• Prevent entry of foreign objects during servicing
the cooling system parts.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-5
component units and accessories from which the vehicles are manufactured.

Repair Manual
In Car Repairs
Engine Coolant Replacement/Filling
and Bleeding Procedure:
1. Park the vehicle on flat-horizontal surface by
applying the parking brake.
2. Verify that the engine and coolant are at normal
temperature. Never remove the pressure cap if
engine is still hot.
3. Turn cabin heater Knob in full hot position
throughout the coolant draining process.
4. Keep a suitable container below the radiator
drain plug to collect the coolant that will drain.
5. Slowly open the degassing tank cap. Never
open the pressure cap quickly. This will cause
progressive pressure release in the system.
6. Remove the drain cock (A) from the radiator bot-
tom right side corner. Drain the coolant com-
pletely. Refit the drain cock. Fill the new
(prescribed) coolant mixture in the system from
the degassing tank filler neck.
A
7. Loosely fit the degassing tank pressure cap. Do
not tighten it fully.
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-6 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN-00162
Engine Cooling Nov 2011/ Rev 2
8. Coolant should be filled till the fill level reaches
just below the 'MAX' marking on the degassing
tank. Check the system for any leakages.
MAX
MIN
9. Start the engine and run it at approximately 2000
to 2200 rpm for approximately 5 to 10 minutes.
10. Press the accelerator pedal slowly then release
it instantly. Repeat this cycle multiple times for
approximately 5 - 10 minutes.
CAUTION
Care should be taken, as the cap is not tight-
ened fully till now, there could be coolant
splashes near the degassing tank.
11. Stop the engine. Press/release the coolant
hoses so as to drive the entrapped air to some
extent.
12. Fully tighten the pressure cap on degassing
tank.
13. Start the engine and warm it until thermostat
valve opens. This can be verified by touching the
radiator inlet hose with hand and feeling the
warm coolant flowing inside it.
14. Stop the engine and remove the pressure cap.
Let the engine cool down.
15. Check the coolant level in degassing tank. If
required, add coolant so as to bring the level
between 'MIN' and 'MAX' markings. Tighten the
pressure cap fully over degassing tank.
CAUTION
Ensure that there are no leakages in the com-
plete cooling system.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

16. Once any rework/service is done on cooling 4. Remove the drain plug (A) from the radiator, and
system, It is highly recommended that coolant drain the coolant completely from the radiator.
level is checked. While checking the level, the
vehicle should be parked on flat-horizontal sur-
face and coolant should be at normal room tem-
perature.

Cooling System Draining

1. Release the cooling system pressure by slowly A
turning the degassing tank cap.

DANGER
Never open the degas tank pressure cap when
the engine is hot. The escaping steam will
cause severe burns and/or injuries.
5. Install the radiator drain plug after draining the
coolant and lower the vehicle to the ground.
A
Notice
E
LY IMIL
ON AX L
E M
US A M OI
DR IU
IN
AH PREM
M

Always replace the coolant at specified ser-

vice intervals.

Water Pump Leakage Test

Typical sign of failed water pump is leakage through
the seal and bearings. Water pump has a small hole
below where the coolant will seep out if the seal or
bearing is failed. If the water pump is leaking replace
the pump as soon as possible. Water pump failure
can be confirmed by below steps:
2. Remove the degassing tank cap. 1. Rotate the water pump pulley and check for free
3. Raise and support the vehicle. For additional rotation.
information refer to Jacking and Lifting 2. Check for water leakage through the leakage
removal and installation Section. hole.

Cooling System Leakage Test

DANGER 1. Supply low pressure air into the system which
causes the coolant to pour or drip from any leak
Remove the degassing tank cap covered with
in the system.
a thick cloth to prevent scalding resulting from
the cooling system pressure. 2. Using the pressure tester which is essentially a
hand-operated air pump, pressurize the system
for leak detection.
3. Install the pressure tester on the degassing tank
filler neck and check for coolant leakages from
cooling system.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-7
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Radiator Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer to
Battery removal and installation Section.

A 2. Remove the coolant drain plug (A) and drain the

coolant from the RHS bottom corner of the radia-
D tor.

B Notice
Place a container beneath the radiator to avoid
spillage of coolant on shop floor.

A. Thermostat
DANGER
B. Inlet Tank Do not remove the drain cock when engine is
hot with pressurized coolant. Serious burns
C. Core will occur due to splashing of hot coolant.
D. Outlet Tank
The radiator is a heat exchanger that removes the
heat from the coolant passing through it. The
coolant flows inside the Radiator from RH to LH.
The cooling air flows outside the Radiator. The heat
exchange is between the coolant to air.
A

3. Remove the NVH cover of the engine. For addi-

A
tional information refer to NVH Cover
removal and installation Section.
4. Remove the front bumper. For additional infor-
mation refer to Front Bumper removal and
A. Drain Cock installation Section.
Drain Cock Used to Drain the Coolant during
Service. Drain Cock is located in the Inlet tank side.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-8 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

5. Remove the two 10mm power steering cooler 8. Using the grip plier, compress the hose securing
bracket mounting bolts (A) from the radiator clips (A), remove the radiator inlet hose and radi-
cross bar. ator bypass hose (B) from the radiator.

A B

A
A A

6. Remove the two front bumper cross bar. For
additional information refer to Front Bumper
removal and installation Section.
7. Pull the four locks (A) from both sides of the
radiator, and move the A/C condenser
assembly aside.
9. Using the grip plier, compress the hose securing
clip (A) and remove the radiator to degas tank
hose (B) from the radiator.
B

A
A
10. Using the grip plier, compress the hose securing
clip (A) and remove the radiator bottom hose
(B).

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-9
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

11. Remove the two 10mm bolts from both sides of 14. Separately remove the radiator assembly from
the radiator top mounting brackets and detach the radiator support cross bar.
the radiator top mounting brackets.

Inspection
12. Lift the radiator and partially tilt the radiator
assembly (A). 1. Check the radiator for leakages due to core
damage or mounting damage. Replace the radi-
ator if required.

Installation
1. To install, reverse the removal procedure.

A 2. Refill the engine coolant. For additional infor-

mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

3. Check for Leakages. For additional informa-

tion refer to Cooling System Leakage Test
Section.

13. Remove the 10mm mounting bolts (A) from both

sides of the radiator and detach the radiator fan
assembly.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-10 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Radiator Support Cross Bar / 8. Release the lock (A) and lift the lever (B)
upwards and disconnect the connector from the
Front End Module ECU.

9. Remove the four 10mm mounting bolts (A) from

Removal the ECU and remove the ECU.
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer to
Battery removal and installation Section.
A
2. Remove the front bumper. For additional infor-
mation refer to Front Bumper removal and
installation Section.
3. Remove the two front bumper cross bar. For
additional information refer to Front Bumper
Cross Bar removal and installation Section.
4. Remove the headlamps from both sides. For
additional information refer to Headlamp
removal and installation Section.
5. Remove the condenser. For additional infor-
mation refer to A/C Condenser removal and
installation Section. 10. Remove the 10mm intercooler mounting bracket
6. Remove the radiator. For additional informa- bolts (A) from the radiator front side.
tion refer to Radiator removal and installa-
tion Section.
7. Remove the cooling fan. For additional infor-
mation refer to Assembly Electric /Cooling
Fan and Shroud with Flaps removal and
installation Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-11
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

11. Unlock the three wiring harness lock clips (A) 14. Remove the 10mm degassing tank mounting
from the radiator support cross bar. bolt (A) from the radiator support cross bar.

A
A

12. Pull out the bonnet cable lock pin (A) from the 15.Remove the 12mm top mounting bolts (A) from
latch and remove the cable. LHS and RHS of the radiator support cross
bar.
A
A A

13. Remove the 10mm mounting bolt (A) from the

wiper reservoir neck.

E
LY IMIL
ON AX L
E M
US A M OI
DR IU
IN
AH PREM
M

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-12 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

16. Remove the 10mm bolt (A) from the air duct Degassing Tank
hose mounting clamp.

MAX

MIN

17. Remove the eight 13mm center mounting bolts Function of the Degassing tank is to remove air
(A) from the radiator support cross bar (B) and bubbles or vapor from the cooling system. Proper
separately remove the radiator support cross filling of the coolant inside the cooling system is
bar. must to pressurize the system at 2.1Bar absolute.

Removal
1. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.

Notice
Place a container beneath the radiator to
avoid spillage of coolant on shop floor.
B A

DANGER
Do not remove the drain cock when engine is
Installation hot with pressurized coolant. Serious burns
1. To install, reverse the removal procedure. will occur due to splashing of hot coolant.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

3. Check for Leakages. For additional informa-

tion refer to Cooling System Leakage Test
Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-13
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

2. Using the grip plier, compress the degas inlet 4. Remove the four 10mm mounting bolts (A)
hoses securing clip (A) and pull out the inlet from the coolant degassing tank and detach
hose (B) from the coolant degassing tank. the degassing tank.

A
M
ON
LY IMIL
E MAX L
US A M OI
IN
DR IU
AH PREM
E

B M
ON
LY IMIL
E MAX L
US A M OI
IN
DR IU
AH PREM
E

A
A

3. Using the grip plier, compress the radiator to Inspection

degas tank hose and degas tank to engine
1. Check the coolant degassing tank thoroughly
hose securing clips (A) and pull out the
for any damage or leakage and replace if
radiator to degas tank hose and degas tank to
required.
engine hoses (B) from the coolant degassing
tank. Installation
1. To install, reverse the removal procedure.
LY IMIL
ON AX L
E
2. Refill the engine coolant. For additional infor-
B
E M

mation refer to Engine Coolant Replacement/

US A M OI
DR IU
IN
AH PREM
M

A
Filling and Bleeding Procedure: Section.
A

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-14 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Radiator to 5. Using a grip plier, compress the degassing

hose securing clip (A) and pull out the radiator
Degas Tank to degas tank hose (B) from the radiator.

The air bubbles from Radiator will be entrapped Installation

through this hose.
Notice
Removal
Always fix the white paint marking side of
1. Disconnect and isolate the negative terminal of
the hose to the Engine side and yellow paint
the battery. For additional information refer
marking to the Radiator side.
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
1. To install, reverse the removal procedure.
from the radiator. For additional information
refer to Cooling System Draining Section. 2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
3. Remove the front bumper grill. For additional
Filling and Bleeding Procedure: Section.
information refer to Front Bumper Grill
removal and installation Section.
4. Using a grip plier, compress the degassing
hose securing clip (A) and pull out the radiator
to degas tank hose (B) from coolant degassing
tank and detach the radiator to degas tank
hose.

E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN
AH PREM
M

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-15
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Engine to Installation

Degassing Tank Notice
Always fix the white paint marking side of
the hose to the Engine side and yellow paint
marking to the Radiator side.

1. To install, reverse the removal procedure.

2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

The air bubbles from water outlet pipe will be

entrapped through this hose.

Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using the grip plier, compress the degas inlet
hoses securing clips (A) connected to the
water outlet pipe and degassing tank to
remove the inlet hose (B).

ON
LY IMIL
A
E

E MAX L
US A M OI
DR IU
IN
AH PREM
M

B
A

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-16 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Degas Tank to 4. Using the grip plier, compress the outlet hose
securing clips (A) and pull out the outlet hose
Engine (B) from the water pump side and detach the
outlet hose.

During initial filling coolant will be circulated from

De-gassing tank to the engine through this hose. Installation
Removal Notice
1. Disconnect and isolate the negative terminal of
Always fix the white paint marking side of
the battery. For additional information refer
the hose to the Engine side and yellow paint
to Battery removal and installation Section.
marking to the Radiator side.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
1. To install, reverse the removal procedure.
refer to Cooling System Draining Section..
2. Refill the engine coolant. For additional infor-
3. Using the grip plier, compress the degas outlet
mation refer to Engine Coolant Replacement/
hoses securing clips (A) and pull out the outlet
Filling and Bleeding Procedure: Section.
hoses (B) from the coolant degassing tank.

A B
E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN
AH PREM
M

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-17
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Radiator Bypass 4. Using the grip plier, compress the assembly
radiator inlet hose securing clip (A) and pull out
the assembly radiator inlet hose (B) connected
to the thermostat valve and the coolant outlet
pipe.

B A
A

A. Engine Side B
B. Radiator Side
When thermostat closed (coolant temperature <
92°C) the coolant water will bypass from the Installation
Radiator.
Notice
Removal
Always fix the white paint marking side of
1. Disconnect and isolate the negative terminal of
the hose to the Engine side and yellow paint
the battery. For additional information refer
marking to the Radiator side.
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
1. To install, reverse the removal procedure.
from the radiator. For additional information
refer to Cooling System Draining Section. 2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
3. Using the grip plier, compress the radiator inlet
Filling and Bleeding Procedure: Section.
hose securing clip (A) and pull out the
assembly radiator inlet hose (B) connected to 3. Check for Leakages. For additional informa-
the thermostat valve. tion refer to Cooling System Leakage Test
Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-18 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Radiator Inlet Installation

Notice
Always fix the white paint marking side of
the hose to the Engine side and yellow paint
marking to the Radiator side.

1. To install, reverse the removal procedure.

2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
B
A 3. Check for Leakages. For additional informa-
tion refer to Cooling System Leakage Test
Section.

A. Engine Side
B. Radiator Side
Radiator Inlet Hose in which the coolant form
Engine will enter in to radiator for removing the
Heat from coolant.

Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the assembly
hose radiator inlet securing clip (A) and pull out
the assembly hose radiator inlet (B) from the
radiator and coolant inlet pipe.

B
A

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-19
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Hose Radiator Outlet 4. Using a grip plier, compress the assembly
hose radiator outlet securing clips (A) and
remove the assembly hose radiator outlet (B)
from the outlet pipe.
A

B
A
A. Engine Side
B. Radiator Side
Outlet Hose connected on radiator outlet tank side Installation
which will send the cooled coolant to the engine.
Notice
Removal
Always fix the white paint marking side of
1. Disconnect and isolate the negative terminal of
the hose to the Engine side and yellow paint
the battery. For additional information refer
marking to the Radiator side.
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
1. To install, reverse the removal procedure.
from the radiator. For additional information
refer to Cooling System Draining Section. 2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
3. Using a grip plier, compress the assembly
Filling and Bleeding Procedure: Section.
hose radiator outlet securing clips (A) and
remove the assembly hose radiator outlet (B) 3. Check for Leakages. For additional informa-
from the radiator bottom side. tion refer to Cooling System Leakage Test
Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-20 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

EGR Hose (EGR Cooler to Installation

1.To install, reverse the removal procedure.
Coolant Outlet Hose) 2. Refill the engine coolant. For additional infor-
Removal mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer 3. Check for Leakages. For additional informa-
to Battery removal and installation Section. tion refer to Cooling System Leakage Test
2. Remove the drain plug and drain the coolant Section.
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the EGR cooling
water outlet hoses securing clip (A) and
remove the EGR water outlet hose (B)
connected to the EGR cooler and coolant
outlet pipe.

4. Using a grip plier, compress the EGR cooling

water outlet hose securing clip (A) and
disconnect coolant outlet hose (B) from the
coolant outlet pipe.

B
A

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-21
component units and accessories from which the vehicles are manufactured.

Repair Manual
EGR Hose (Engine to
Cooler)
Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the EGR cooling
water inlet hoses securing clips (A) and
remove the EGR water inlet hose (B).
A
B
Installation
1.To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
3. Check for Leakages.For additional informa-
tion refer to Cooling System Leakage Test
Section.
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-22 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN-00162
Engine Cooling Nov 2011/ Rev 2
EGR Heater Hoses (Inlet and Outlet)
Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator.For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the securing clips
(A) and remove the heater inlet and outlet
hoses (B) from pre-heater pipes.
B A
A
B
4. Using a grip plier, compress the securing clips
(A) and remove the heater inlet and outlet
hoses (B) from water outlet pipe and detach
the heater hoses.
B
B
A
Installation
1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

Repair Manual
3. Check for Leakages. For additional informa-
tion refer to Cooling System Leakage Test
Section.
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN-00162
Engine Cooling Nov 2011/ Rev 2
Oil Cooler Hoses (Oil Cooler to
Coolant outlet Hose and Engine)
Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the engine oil
cooler inlet and outlet hoses (A) and separately
remove the Oil cooler hoses (B) from the
engine oil cooler.
A A
A
B
Installation
1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
3. Check for Leakages. For additional informa-
tion refer to Cooling System Leakage Test
Section.
All copyrights reserved by
4-23

Repair Manual
Coolant Outlet Joint Hose
Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
3. Using a grip plier, compress the securing clips
(A) and separately remove the coolant outlet
joint hose (B) from the coolant outlet pipe.
A B A
Installation
1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
3. Check for Leakages. For additional informa-
tion refer to Water Pump Leakage Test Sec-
tion.
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-24 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN-00162
Engine Cooling Nov 2011/ Rev 2
Thermostat
Thermostat valve is a coolant flow control device
which is operated by virtue of heat received from
the engine coolant flowing across it. Thermostat
valve helps in regulating the operating temperature
of engine by controlling the amount of coolant
flowing through the radiator.
When engine and coolant are relatively colder, the
thermostat valve remains closed thereby preventing
the coolant from flowing through the radiator.
Coolant flows directly to the water pump inlet.
Because of this, coolant and engine progressively
get warmer. Once engine and coolant are warm
enough, the valve start opening up, thereby
allowing a portion of coolant to flow through the
radiator.
Thus thermostat keeps the coolant temperature
within the range to improve the combustion efficiency
of the engine.
Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.
2. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Radiator removal and installation
Section.
Notice
Place a container beneath the radiator to
avoid spillage of coolant on shop floor.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

6. Remove the four 10mm thermostat mounting

bolts and nuts (A) from the thermostat and
DANGER separately remove the thermostat assembly.
Do not remove the drain cock when the engine
is hot and pressurized. Serious burns will
occur due to splashing of hot coolant.

3. Remove the NVH cover. A

4. Using the grip plier, compress the assembly
radiator inlet hose securing clip (A) and
remove the assembly radiator inlet hose (B)
from the thermostat housing.

7. Remove the thermostat O-ring (A) from the

B thermostat.

A
5. By using a grip plier, compress the assembly
hose radiator inlet securing clip (A) and
remove the assembly hose radiator inlet (B)
from the thermostat housing.

Installation
1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
B mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
A

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-25
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Water Pump 3. Remove the 14mm banjo mounting bolt (A)

from the turbocharger oil inlet pipe attached to
the cylinder block.

A centrifugal water pump is used to circulate the

coolant through the water jackets, cylinder head, 4. Fix the water pump pulley locking tool (A)
hoses and radiator. The water pump is belt driven (Special Tool Part No:0304GAM0001ST), into
by the engine main drive pulley. the water pump pulley bolt.
The water pump impeller is pressed onto the shaft.
The shaft is supported on two bearings that are Notice
integral to the shaft. The water pump seal is By using the special tool, loosen the four wa-
located between the impeller and the housing. ter pump pulley mounting bolts.
The housing has a small hole to allow the seepage
to escape. That also acts as an indication point if
the water pump seal fails.
The water pump is not serviceable and has to be
changed as an assembly.

Removal
1. Remove the drive belt. For additional A
information refer to Accessory Drive Belt
removal and installation Section.

2. Remove the coolant drain plug and drain the

coolant. For additional information refer to
Cooling System Draining Section.

Notice
Place a container beneath the radiator to
avoid spillage of coolant on shop floor.

DANGER
Do not remove the drain cock when the engine
is hot and pressurized. Serious burns will
occur due to splashing of hot coolant.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-26 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

5. Remove the four 12mm mounting bolts (A) from Installation

the water pump pulley and detach the water 1. To install, reverse the removal procedure.
pump pulley.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
A

6. Remove the five 12mm mounting bolts (A)

from the water pump.

7. Separately remove the water pump (A) from

the drive shaft side.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-27
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Engine Oil Cooler 3. Using a grip plier, compress the securing clips
(A) and remove the inlet and outlet hoses (B)
from the oil cooler.

B
A

The multi plate aluminum oil cooler in the engine

coolant system provides passages in which some 4. Remove the three 12mm oil cooler mounting
are used for oil circulation and some passages are bolts (A) from the cylinder block and separately
used for coolant circulation. Hot oil from the remove the engine oil cooler assembly (B).
cylinder block enters the cooler and circulates
through the passages which are surrounded by the
cooling water on both sides. The cooled oil then
flows from the cooler into the oil filter.
The cooling water for the cooler is taken from the B
cylinder block water gallery.

Removal
1. Remove the intercooler. For additional
information refer to Intercooler removal and
installation Section. A
2. Using a oil filter wrench, remove the oil filter
(A) from the engine oil cooler assembly.

A Installation
Notice
While removing the engine oil cooler, replace
the engine oil cooler gasket.

1. To install, reverse the removal procedure.

2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-28 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Coolant Temperature Sensor 3. Remove the 19mm coolant temperature sensor

lock nut (A), and separately remove the
coolant temperature sensor (B) from the
engine coolant inlet pipe.

A B

Coolant Temperature sensor is a made of semi

conductor material (NTC) which changes its
resistance when exposed to variable temperature
source. Resistance decreases as temperature
Installation
increases. It is located on the water outlet box, 1. To install, reverse the removal procedure.
near thermostat. Monitors the coolant temperature. 2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Removal Filling and Bleeding Procedure: Section.
1. Remove the intercooler. For additional
information refer to Intercooler removal and
installation Section.

DANGER
Do not remove the drain cock when engine is
hot with pressurized coolant. Serious burns
will occur due to splashing of hot coolant.

2. Press the lock and pull out the electrical

connector (A) from the coolant temperature
sensor.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-29
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Assembly Electric /Cooling Fan 3. Remove the two 10mm power steering cooler
bracket mounting bolts (A) from the radiator
and Shroud with Flaps cross bar.

A A
B
A. Fan Side Connector 4. Using a grip plier, compress the securing clip
B. Rubber Flaps (A) and remove the radiator overflow hose (B).
The Electric fan pulls the ambient air through the
radiator core that cools the hot water circulating B
through the radiator. The fan will be connected
through connector to the electrical circuit.The
rubber flap openings provided on Radiator shroud A
to aid the extra air through the Radiator at high
vehicle speeds. The Fan and Shroud Assembly
Mounted on Radiator Top with bolt and bottom by
snap Fit.

Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer
to Battery removal and installation Section.

2. Remove the radiator. For additional 5. Press the lock and pull out the electrical
information refer to Radiator removal and connector (A) from the cooling fan.
installation Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-30 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

6. Remove the two top mounting shroud bolts (A), 8. Lift the radiator and slightly rotate it towards
and remove the top mounting shroud from both the LHS and separately remove the cooling fan
sides of the radiator. assembly (A) from the radiator.

Notice
CAUTION Electric fan and fan motor are not separately
Do not remove the radiator bottom hose to serviceable. They should be replaced as a
avoid coolant loss. single unit only.

7. Unlock the bottom mounting snap fit (A) of the Installation

cooling fan. 1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-31
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Cooling Fan Resistor Installation

1. To install, reverse the removal procedure.

Removal
1. Press the lock and pull out the electrical
connectors (A) from both sides of the fan
motor resistor.

2. Remove the resistor mounting screw (A) from

the shroud, and open the lock and separately
remove the cooling fan resistor.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-32 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Cooling Fan Shroud with Flaps Diagnosis and Testing

Inspection and Verification
1. Visually inspect the cooling system for any
noticeable signs of leakages and mechanical
damage.
2. If an obvious cause is found, correct the same
before proceeding to the next step.
3. If the cause is not found visually, refer to the
troubleshooting chart given below.
4. All the components should be inspected for
wear and replaced if required.
Mechanical
• Check the electric fan for any damage.

Removal • Check for any leakage in the degassing tank

and radiator.
1. Disconnect and isolate the negative terminal of
• Check the hoses in the cooling system for any
the battery. For additional information refer
damage or leakage.
to Battery removal and installation Section.
• Check the thermostat and its housing for any
2. Remove the cooling fan. For additional leakages and damages.
information refer to Assembly Electric /
Cooling Fan and Shroud with Flaps removal
and installation Section..

3. Remove the cooling fan shroud mounting

screws (A) and detach the cooling fan shroud
with flaps.

Installation
1. To install, reverse the removal procedure.
2. Refill the engine coolant. For additional infor-
mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-33
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Troubleshooting Chart
Symptom Possible Causes Remedy

Engine does not 1. Thermostat valve stuck at partial/fully 1. Replace it if necessary.

reach normal open condition.
operating
temperature.

1. Mechanical damage in shrouds. 1. Tighten the bolts on shroud, and

replace the shrouds if necessary.
2. Loose water pump impeller or bearing 2. Repair or replace the water pump.
failure.

Cooling system 3. Belt damaged. 3. Replace the belt.

component
4. Stretched or damaged fan belt. 4. Replace the serpentine belt.
noisy.
5. Rough surface on the drive pulley. 5. Replace the drive pulley.

6. Improper belt alignment. 6. Check the belt alignment and rectify.

7. Cooling fan bearing failure. 7. Replace the cooling fan.

1. Coolant level is too low or too high. 1. Maintain the coolant level between
MIN and MAX marking on the degas-
sing tank when coolant is at normal
room temperature and the vehicle is
parked on flat-horizontal surface.
2. Leakages at inner side the cooling 2. Check and repair any coolant leakag-
system. es from radiator, hose, joints, thermo-
stat housing, water pump, cylinder
head, crank case, cabin heater etc.
3. External blockages in heat exchang- 3. Check and clean/clear external block-
Engine getting ers restricting the air flow. ages from core/fins of the radiator,
over heated (ex- condenser.
cessively high
engine coolant 4. Contaminated or aged coolant mixture 4. Drain and refill specified coolant mix-
temperature) inside system. ture.

5. Thermostat valve stuck at partial/fully 5. Check and replace the thermostat

closed condition. valve if necessary.

6. Insufficient water flow due to faulty wa- 6. Check the seal, shaft and impeller and
ter pump. replace the water pump if necessary.

7. Faulty pressure cap. 7. Check and replace the pressure cap if

necessary.

8. Faulty or damaged Drive Belt. 8. Replace the Drive Belt.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-34 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Symptom Possible Causes Remedy

1. Fan blades striking a surrounding ob- 1. Locate the fan blade contact and re-
ject. pair it if necessary.
Noisy cooling 2. External blockages in the heat ex- 2. Check and clean/clear external
fan. changers restricting the air flow. blockages from core/fins of radiator,
condenser.
3. Defective cooling fan bearing. 3. Replace the cooling fan.

1. Low cylinder head torque. 1. Replace the cylinder head gasket, and
Coolant entry
adjust the torque as per procedure.
into crankcase
or cylinder 2. Faulty cylinder head gasket. 2. Replace the cylinder head gasket.
black.

1. Coolant level is too high. 1. Park the vehicle on flat horizontal sur-
face and allow the coolant to cool
down to ambient temperature. Check
and correct coolant level.
Coolant spill 2. Coolant level is too high and insuffi- 2. Check wether the cap is tightened suf-
over from de- cient sealing between the degassing ficiently. Check sealing of pressure
gassing tank. tank neck and pressure cap. cap. If required replace the degassing
tank assembly.

3. Engine getting over heated. 3. Follow the corrective measures as

suggested for overheating in the trou-
ble shooting chart.

1. Coolant Mixes with Oil. 1. Check and rectify.

2. Oil Cooler Punctured/Damaged be- 2. Carry out the Pressure Test.

Observed Wa- tween Coolant and oil Passage.
ter in Oil Cooler 3. Check and rectify.
3. Blow holes causing the coolant and oil
to mix with each other in crankcase
galleries.

High Tempera- 1. Faulty coolant temperature sensor. 1. Connect diagnostic tool and rectify.
ture Indication

1. Restricted return inlet in water pump. 1. Remove restriction.

No coolant flow 2. Heater hoses collapsed or restricted. 2. Pressure test to isolate & repair.
trough Heater
Core 3. Restricted heater core. 3. Remove flash or restriction.
4. Restricted outlet in the thermostat 4. Remove restriction.
housing.

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-35
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Component Inspection Table

Component Inspection Action

Drive belt 1. Check the accessory drive 1. Replace the drive belt.
belt for abrasion, cracking,
improper installation, uneven
rib wear, misalignment,
chunk-out, gravel penetration
and piling.

Water Pump 1. Check for leakages. 1. Replace the water pump.

2. Check for bearing noise. 2. Replace the water pump.

Cooling Fan 1. Check for physical damage. 1. Replace the fan.

2. Check for fan noise. 2. Replace the fan.

Degassing Tank 1. Check for physical damage 1. Replace the degas tank.
like cracks, wear and tear.

Thermostat 1. Check for physical damage. 1. Replace the thermostat as-

2. Check thermostat normal op- sembly.
eration. 2. Perform thermostat valve test
and replace if required.

Radiator 1. Check for physical damage, 1. Replace radiator if required.

fin distortion etc. 2. Flush the radiator, replace
2. Check for radiator blockage. only if required.

Pressure cap 1. Check the cap for physical 1. Replace if required.

damage.
2. Check pressure cap for leak- 2. Perform pressure cap test
age. and replace if required.

Coolant Hoses 1. Check hoses for cracks, dis- 1. Replace the concerned hose
tortion or flaring. and perform coolant pressure
test.

Mahindra Special Tools (MST)

MST NO Tool Name Illustration

0304GAM0001ST Water pump pulley locking tool

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-36 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Technical Specification
Component Description Specification

Type Cross Flow

Coolant Mixture 70:30 (Water: Ethylene glycol)

Radiator MAHINDRA "MAXIMILE ULTRA 8.0 Liters
COOL"
(READY TO USE COOLANT. NO
NEED TO MIX WATER)

Type Electric

Fan and Shroud Max fan speed - 2511RPM

Speed
Min fan speed - 1400 RPM

Type of Thermostat Wax type

Thermostat Thermostat starts opening @ 92 + 2°C with 0.1mm travel

Thermostat complete opening @ 98 + 2°C with 8mm lift

Max coolant volume 1.4 Litres

Min Coolant Volume 0.5 Litre

Degassing tank
Expansion Volume 0.6 Litre

Total Volume 2.0 Litres + 0.2

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 4-37
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2

Torque Specification
Bolt Torque in
Part Place of Application Quantity
Specification Nm

SCREW HEX FL
Radiator assem- Radiator assembly to front end carrier
M6X1X20X8.8XG 2
bly bracket
R

SCREW HEX FL
Degassing tank
M6X1X20X8.8XG Degassing tank to BIW 4 10.0±2.0
assembly
R

SCREW HEX FL
Byepass hose
M6X1X20X8.8XG Byepass hose bracket mounting 1
bracket
R

BOLT HEX FL
CRFM seals M6X1X25X8.8XZ CRFM seals mounting on condenser 4
N.3
8.0~10.0
SCREW HEX FL
Top seal M6X1X15X8.8XG Top seal mounting on front end carrier 2
R

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
4-38 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.