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Chapter 3
Cooling, heating and air conditioning systems
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised with expansion tank/bottle and front-mounted radiator,
electric cooling fan, coolant pump and thermostat
Pressure cap setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 or 1.0 bar (according to engine)
Thermostat
Start-to-open temperature:
XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79° to 82°C
XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C
TU9 series, TU3 series and TU1 series (Van) engines . . . . . . . . . . . . 88°C
TU1 series (except Van) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83°C
Fully-open temperature:
XU, XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 93°C
TU9 series, TU3 series and TU1 series (Van) engines . . . . . . . . . . . . 102°C
TU1 series (except Van) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96°C
Torque wrench settings Nm lbf ft
Coolant pump attachments:
XV, XW, and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 10
XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
TU series engines:
Housing inlet elbow (aluminium block engines) . . . . . . . . . . . . . . . 8 6
Housing bolts (aluminium block engines):
Small bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Large bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Coolant pump bolts (cast-iron block engines): . . . . . . . . . . . . . . . . 15 11
Air conditioning system check . . . . . . . . . . . . . . . . . . . .See Chapter 1
Air conditioning system - general information and precautions . . . . 10
Antifreeze - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Coolant level check . . . . . . . . . . . . . . . . . . . . . . .See
“Weekly checks”
Coolant pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling system - draining . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Cooling system - filling . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Cooling system - flushing . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Cooling system electrical switches and sensors - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cooling system hoses - disconnection and renewal . . . . . . . . . . . . . 2
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Heater assembly - removal, dismantling, reassembly and refitting . . 9
Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator cooling fan - removal and refitting . . . . . . . . . . . . . . . . . . . 6
Thermostat - removal, testing and refitting . . . . . . . . . . . . . . . . . . . . 4
3•1
Specifications
Contents
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
5
4
3
2
1