Removing
− Before starting to remove parts, carry out the following operations:
- A) Drain the coolant.
- b) Remove the engine crankcase guard.
- V) Drain the working fluid of the variator or automatic transmission.
- G) Remove the intake duct
- d) Remove the battery and battery tray.
− Removal of parts is carried out in the order of numbers indicated in the figure "Removing the radiator and electric fan".
Removing the radiator and electric fan (engine 4G93-MPI). 1 - drain plug, 2 - radiator cap, 3 - expansion tank hose, 4 - expansion tank, 5 - upper radiator hose, 6 - lower radiator hose, 7 - automatic transmission fluid cooler hose connection, 8 - upper radiator support, 9 - radiator, 10 - lower radiator support, 11 - automatic transmission fluid cooler hoses assembly, 12 - diffuser and radiator and air conditioning condenser electric fans assembly, 13 - radiator fan, 14 - radiator fan motor, 15 - electric fan controller, 16 - condenser fan air conditioner, 17 - air conditioner condenser fan motor, 18 - fan diffuser.
Removing the radiator and electric fan (except for 4G93-MPI engine). 1-drain plug, 2 - radiator cap, 3 - expansion tank hose, 4 - expansion tank, 5 - upper radiator hose, 6 - lower radiator hose, 7 - CVT fluid cooler hose connection, 8 - upper radiator support, 9 - radiator, 10 - lower radiator support, 11 - variator fluid cooler hose assembly, 12 • diffuser and radiator and air conditioning condenser fan assembly, 13 - radiator and air conditioning condenser fan, 14 - radiator and air conditioning condenser fan motor, 15 - controller electric fan, 16 - fan diffuser.
− When removing parts, pay attention to the following operations:
1. Removing the upper and lower radiator hoses.
Before disconnecting the upper and lower radiator hoses, mark the relative position on the hose and hose clamp.
Attention: after disconnecting the hoses from the radiator, it is necessary to close the holes in the hose and radiator with plugs to prevent dust or foreign particles from entering them.
2. Removing the cooler hose of the working fluid of the variator or automatic transmission.
After disconnecting the hose from the radiator, plug the holes in the hose and radiator to prevent dust or foreign particles from entering them.
Examination
1. Checking the radiator.
A) Check for foreign particles (dirt, leaves, fluff, etc.) between radiator fins. Clean with compressed air if necessary.
b) Check the radiator fins for bending or damage.
V) Check the radiator for damage and deposits of scale, rust or corrosion.
G) Check the radiator hoses for cracks, damage or wear.
d) Check expansion tank for damage.
e) Check the radiator cap spring for wear and damage.
and) Check the radiator cap gasket for damage or cracks.
2. Fan check.
A) Check fan blades for damage or cracks.
b) Check for cracks or damage around the bolt holes in the fan hub.
V) If any part of the fan is damaged, replace the fan assembly.
3. (Except 4G93-MPI engine) Checking the electric fan controller.
A) Disconnect the radiator fan and A/C condenser motor connector.
b) Start the engine and leave it to idle.
V) Turn on the air conditioner and leave the engine running to warm up the coolant to a temperature of approximately 80°C or more.
G) Measure the voltage between the terminals of the fan controller connector and check that the voltage value changes in accordance with the points indicated (I) - (III).
(I) 0V
(II) 8.2±2.6V
(III) Battery voltage (aircraft networks) +2.6V
d) If the voltage value does not change according to the above points, replace the electric fan controller.
4. (Engine 4G93-MPI) Checking the electric fan controller.
A) Disconnect the fan controller connector.
b) Turn on the ignition (ignition key in position "ON") and measure the voltage between the terminals of the connector disconnected from the controller.
Rated value - battery voltage
V) Connect the fan motor controller connector and disconnect the A/C condenser fan motor connector.
G) Make sure the air conditioner is off (switch in position "OFF"), then start the engine and let it idle.
d) Measure the voltage between the terminals of the fan controller connector from which the connector was disconnected in subparagraph "V".
Rated value - 1V and below
e) Turn on the air conditioner (switch in position "ON").
and) Verify that the radiator fan is rotating, then measure the voltage across the terminals of the fan controller connector and verify that the voltage value changes as indicated (I) - (II).
(I) 8.2±2.6 V
(II) Battery voltage (aircraft networks) +2.6V
h) If the voltage value does not change according to the above points, replace the fan controller.
5. Checking the electric fan control relay (except for 4G93-MPI engine) or fan control relay (engine 4G93-MPI).
A) Remove the blower control relay from the relay box in the engine compartment.
b) Check the condition of the circuit between the terminals of the connector according to the table below.
6. Checking the radiator fan motor and air conditioner condenser.
A) To test the operation of the fan motor, connect the battery terminal wires to the motor connector terminals as shown.
b) Check that there is no extraneous noise when the fan rotates.
Troubleshooting on models with an electric fan controller
1. If the radiator fan and condenser fan are not working, then the power line or ground of the electric fan controller is probably broken, or the engine electronic control unit is faulty. One of the following faults may be present:
- A) Fusible link burned out.
- b) Faulty fan control relay.
- V) Faulty fan controller.
- G) Malfunction of the electronic engine control unit.
- d) An open in the wiring harness or poor contact in the connector.
2. If the speed does not switch or the electric fan of the radiator and the condenser of the air conditioner does not turn off, then, probably, the electric fan controller, according to the signals of the electronic engine control unit, gives the wrong mode (rotational speed) operation of the fan motor. One of the following faults may be present:
- A) Faulty fan control relay.
- b) Faulty fan controller.
- V) Malfunction of the electronic engine control unit.
- G) An open in the wiring harness or poor contact in the connector.
3. If the fan motor is not working, the fan motor is probably defective, the fan motor controller is faulty, or there is an open circuit between the controller and the fan motor.
Installation
− Installation of parts is carried out in the reverse order of removal.
− When installing the parts, pay attention to the installation procedure of the lower and upper radiator hoses.
A) When connecting the radiator hoses, put the hose on the branch pipe until it stops against the protrusion of the branch pipe, then tighten the clamp.
b) The hose clamp should always be installed in the position in which the clamp was previously installed. Therefore, before installing the clamp, align the alignment marks on the hose clamp and hose, then connect the hose.
− After completing the installation of the parts, perform the following operations.
A) Install the battery tray and battery.
b) Install the intake duct
V) Fill in the working fluid of the variator or automatic transmission.
G) Install the engine crankcase guard.
d) Refill coolant and check for leaks.