Published: 05-Jul-2011

Engine Cooling - ID4 2.2L Diesel -

Item Specification
Anti-freeze WAS-M97B44-D
Anti-freeze concentration - Will provide frost protection to -40°C (-40°F) 50%
Specific gravity of coolant at 20°C (68°F), to protect against frost down to -40°C (-40°F) 1.068
Item Capacity
Cooling System 10 Liters (17.6 pints) (10.6 quarts)
Radiator 2.3 Liters (4 pints) (2.4 quarts)
Coolant Expansion Tank (To Cold Level) 1.2 Liters (2.1 pints) (1.3 quarts)
Item Description
Cooling system type Pressurized, thermostatically controlled with coolant expansion tank
Radiator Cross flow
Coolant expansion tank Remote with cold level fill mark
Pressure cap rating 100 kPa (1 bar) (15.9 lbf/in²)
Thermostat: Starts to open 82° C (180°F)
Thermostat: Fully open 96° C (205°F)
Cooling fan Viscous
Cooling fan control Bi-metallic
Cooling fan diameter 475 mm (18.70 inches)
Cooling fan direction of rotation Clockwise when viewed from front of engine
Coolant pump Centrifugal flow impeller, belt driven from the crankshaft
Torque Specifications

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Description Nm lb-ft
Coolant bleed screw(s) 3 2
Coolant pump bolts 23 17
Coolant pump outlet manifold 10 7
Coolant pump hose clip 3 2
Viscous coupling bolts 10 7
Expansion tank bolt 10 7
Charge air cooler to radiator bolts 20 15
Charge air cooler inlet and outlet hose clips 3 2
Charge air cooler bracket bolts 9 7
Power steering reservoir nuts 4 3
 Published: 27-Sep-2011
Engine Cooling - ID4 2.2L Diesel - Engine Cooling
Description and Operation

COMPONENT LOCATION

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Item Part Number Description
1 - Cooling fan
2 - Outlet connector
3 - Radiator upper hose
4 - Coolant pump
5 - Distribution manifold
6 - Bleed screw
7 - Heater return connection
8 - Expansion tank
9 - Heater feed connection
10 - EGR (exhaust gas recirculation) cooler
 11 - EGR valve
12 - Fuel cooler
13 - Engine oil cooler
14 - Thermostat
15 - Radiator lower hose
16 - Radiator
17 - ECT (engine coolant temperature) sensor

OVERVIEW

The cooling system employed is the bypass type, which allows coolant to circulate around the engine and the heater
circuit while the thermostat is closed. The primary function of the cooling system is to maintain the engine within an
optimum temperature range under changing ambient and engine operating conditions. Secondary functions are to
provide:

Heating for the passenger compartment.

For additional information, refer to: Climate Control System (412-00 Climate Control System - General
Information, Description and Operation).
Cooling for:
The EGR valve and EGR cooler.
For additional information, refer to: Engine Emission Control (303-08 Engine Emission Control - ID4 2.2L Diesel,
Description and Operation).
The engine oil cooler.
For additional information, refer to: Engine (303-01 Engine - ID4 2.2L Diesel, Description and Operation).
The fuel cooler.
For additional information, refer to: Fuel Tank and Lines - ID4 2.2L Diesel (310-01 Fuel Tank and Lines - ID4 2.2L
Diesel, Description and Operation).

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The primary components of the engine cooling system are:

A coolant pump
An inlet manifold and an outlet connector
A thermostat
A radiator
An expansion tank
A cooling fan
Connecting hoses and pipes

An ECT sensor for the engine management system is installed in the radiator upper hose.
For additional information, refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - ID4 2.2L Diesel,
Description and Operation).

The coolant is circulated by a centrifugal type pump mounted on the front LH (left-hand) side of the engine and driven by
the accessory drive belt. An outlet hose supplies coolant from the pump to a distribution manifold on the LH side of the
cylinder block. The coolant flows through the cylinder block and cylinder head, to an outlet connector on the front of the
cylinder head, then into the radiator upper hose.

The thermostat, installed between the radiator upper and lower hoses, regulates the coolant flow through the radiator to
provide a rapid engine warm-up and then maintain a stable engine temperature. The outlet from the thermostat is
directed back to the inlet side of the coolant pump.

The radiator is a cross flow type with an aluminum matrix and plastic end tanks. The end tanks have brackets which allow
for the attachment of the fan cowl assembly, charge air cooler and, if fitted, A/C (air conditioning) condenser. The bottom
of the radiator is located in rubber bushes supported by brackets on the chassis longitudinals. The top of the radiator is
located in rubber bushes secured by brackets fitted to the bonnet locking platform.

A connection on the distribution manifold supplies coolant to the engine oil cooler. The return from the engine oil cooler is
connected to the hose between the thermostat and the coolant pump inlet.

The radiator upper hose has a connection for the feed to the heater matrix, EGR valve and EGR cooler. The return is
connected to an inlet on the coolant pump. The heater matrix outlet hose incorporates a bleed screw to bleed air when
filling the cooling system.

The feed for the fuel cooler comes from a connection on the RH (right-hand) end tank of the radiator. The return from the
fuel cooler is connected to the radiator lower hose.

The expansion tank is fitted to the RH suspension turret in the engine compartment. The expansion tank allows for
expansion of the coolant when the engine is hot, and retraction as the engine cools down, through a hose connected to an
inlet on the coolant pump. A hose connected between the upper left corner of the radiator and the expansion tank ensures
there is a constant flow through the expansion tank while the engine is running, to separate out any air in the system. The
expansion tank filler cap provides a service fill and top-up point, and pressurizes the system during operation.

The cooling fan generates additional airflow through the radiator matrix, particularly when the vehicle is stationary. The
cooling fan is an 11-bladed viscous fan, which is attached to a pulley on the engine front cover and driven by the
accessory drive belt. A two-piece shroud provides an air duct between the cooling pack and the fan, and also forms a
protective cover.
Cooling System Schematic

Item Part Number Description

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1 - Heater matrix
2 - Bleed screw
3 - EGR cooler
4 - EGR valve
5 - Cylinder head
6 - Cylinder block
7 - Distribution manifold
8 - Engine oil cooler
9 - Coolant pump
10 - Expansion tank
11 - Radiator
12 - Thermostat
13 - Outlet connector
14 - Radiator upper hose
15 - Radiator lower hose
16 - Fuel cooler

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 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Engine Cooling
Diagnosis and Testing

Overview

For information on the operation of the systems:

REFER to: Engine Cooling (303-03 Engine Cooling - ID4 2.2L Diesel, Description and Operation).

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious mechanical or electrical faults.

Visual Inspection Chart
Mechanical Electrical
Coolant leaks
Fuses
Coolant hoses
Fuse 29, passenger compartment
Coolant expansion tank
Harnesses
Radiator
Loose or corroded connector(s)
Heater core
Cylinder head temperature (CHT) sensor
Accessory drive belt
Engine oil temperature (EOT) sensor
Viscous fan

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step.

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4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before moving
onto the symptom chart or DTC index.
Make sure that all DTCs are cleared following rectification.

Symptom Chart

Symptom Possible cause Action

Coolant loss Hoses
Hose connections
Radiator
Water pump
Heater core Carry out a visual inspection. If there are no obvious leaks, carry out a pressure
Gaskets test using your workshop tester. Rectify as necessary.
Engine casting
cracks
Engine block core
plugs

Overheating Low/contaminated
coolant
Thermostat Check the coolant level and condition. Carry out a pressure test using your
Viscous fan workshop tester. Rectify as necessary. Check the thermostat and rectify as
Cylinder head necessary. Check the viscous fan operation, make sure the viscous fan rotates
temperature freely. Check for obstructions to the air flow over the radiator. Rectify as
(CHT) sensor necessary.
Restricted air flow
over the radiator

Engine not Thermostat

reaching Viscous fan Check the thermostat operation. Check the viscous fan operation, make sure the
normal Electric fan viscous fan is not seized. Rectify as necessary.
temperature
For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00.
REFER to: How To Use This Manual (100-00 General Information, Description and Operation).
 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Cooling System Draining, Filling and
Bleeding
General Procedures

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.

CAUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area
with water.

1. Set the heater controls to Hot.

2. WARNING: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap from the
coolant expansion tank while the system is hot.

Remove the coolant expansion tank cap.

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3. WARNING: Since injury such as scalding could be caused by
escaping steam or coolant, do not remove the cooling system bleed
screw while the system is hot.

Loosen the cooling system bleed screw.

4. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

5. WARNING: Eye protection must be worn.

NOTE: Position a container to collect the coolant.

Disconnect the 2 fuel cooler coolant pipes.

Allow the coolant to drain.

6. WARNING: Eye protection must be worn.

Disconnect the oil thermostat coolant hose.

Allow the coolant to drain.
 7. Remove the container.

8. Connect the 2 fuel cooler coolant pipes.

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9. Connect the oil thermostat coolant hose.

10. CAUTIONS:

Engine coolant will damage the paint finished surfaces. If spilt,

immediately remove the coolant and clean the area with water.

Anti-freeze concentration must be maintained at 50%.

Fill the cooling system expansion tank until the coolant level
becomes static with in the "COLD FILL RANGE".

11. Tighten the cooling system bleed screw.

12. Install the coolant expansion tank cap.

13. CAUTIONS:

Make sure the coolant level remains above the "COLD FILL
 RANGE" lower level mark.

Observe the engine temperature gauge. If the engine starts to

over-heat switch off immediately and allow to cool. Failure to follow
this instruction may cause damage to the vehicle.

Start and run the engine.

Hold the engine speed at 3,000 RPM for one minute.
Return the engine to idle for five minutes.
Hold the engine speed at 3,000 RPM for one minute.
Run the engine until the thermostat opens.

14. WARNING: Release the cooling system pressure by slowly

turning the coolant expansion tank cap a quarter of a turn. Cover
the expansion tank cap with a thick cloth to prevent the possibility
of scalding. Failure to follow this instruction may result in personal
injury.

NOTE: When the coolant bleed is complete and prior to installing the
expansion tank cap, top-up the expansion tank to 30mm above the
maximum level.

Switch the engine off.

Remove the coolant expansion cap, allow the level to settle
and top-up so that the level is 30mm above the upper level.
Allow the engine to cool.

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15. Clean any spilt coolant from the vehicle.

16. Check and top-up the coolant if required.

 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Cooling System Draining and Vacuum
Filling
General Procedures

WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care when
removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth
around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the pressure is
released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant
pressure cap from the coolant expansion tank. Failure to follow these instructions may result in personal injury.

CAUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the vehicle.

Engine coolant will damage paint finished surfaces. If spilled, immediately remove coolant and clean area with water.

1. Set the heater controls to maximum HOT.

2. Remove the hood.

For additional information, refer to: Hood (501-02, Removal and
Installation).

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3. WARNING: Since injury such as scalding could be caused by
escaping steam or coolant, do not remove the filler cap from the
coolant expansion tank while the system is hot.

Remove coolant expansion tank filler cap.

4. Loosen the cooling system bleed screw.

5. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

6. WARNING: Eye protection must be worn.

Position container to collect coolant.

7. Disconnect the 2 fuel cooler coolant pipes.

Allow the coolant to drain.

8. Disconnect the coolant hose from the engine oil cooler.

Release the clip.
Allow the coolant to drain.
 9. Connect coolant hose to engine oil cooler.
Install the clip.

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10. Connect the 2 fuel cooler coolant pipes.
Remove the container.

11. Tighten the cooling system bleed screw.

12. CAUTION: The engine cooling system must be maintained with

the correct concentration and type of anti-freeze solution to prevent
corrosion and frost damage. Failure to follow this instruction may
result in damage to the vehicle.

Prepare a sufficient amount of coolant to the required concentration

and transfer to a container.

13. Install the cooling system vacuum refill adaptor to the

expansion tank.
 14. Install the vacuum filler gauge to the cooling system
vacuum refill adaptor.

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15. Install the venturi tube assembly to the vacuum filler
gauge.

16. NOTE: Make sure both valves on gauge assembly are in

the closed position.

Connect a regulated compressed air supply to the

venturi tube assembly.

17. NOTE: Make sure air cannot enter the hose.

Position the coolant pick-up pipe into a container of clean coolant.

18. Position the evacuated air hose into a container.

19. NOTE: Make sure the coolant supply valve is in the

19. NOTE: Make sure the coolant supply valve is in the
closed position on the vacuum filler gauge assembly.

NOTE: The coolant vacuum fill tool needs an air

pressure of 6 to 8 bar (87 to 116 psi) to operate
correctly.

NOTE: Small diameter or long airlines may restrict

airflow to the coolant vacuum fill tool.

Open air supply valve.

20. Open coolant supply valve for 2 seconds to prime

coolant supply hose.

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21. Apply air pressure progressively until the arrow on the
vacuum filler gauge reaches the green segment.

22. Close air supply valve and disconnect air supply.

23. Allow 1 minute to check vacuum is held.

 24. Open coolant supply valve and allow coolant to be
drawn into system.

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25. When expansion tank is full and coolant movement has ceased close
coolant supply valve.

26. Remove vacuum refill adaptor and gauge from expansion tank.

27. Install the coolant expansion tank filler cap.

28. Install the hood.

For additional information, refer to: Hood (501-02, Removal and
Installation).

29. CAUTIONS:

Make sure the coolant level remains above the "COLD FILL
RANGE" lower level mark.

Observe the engine temperature gauge. If the engine starts to

over-heat switch off immediately and allow to cool. Failure to follow
this instruction may cause damage to the vehicle.

Start and run engine.

Hold the engine speed at 3,000 RPM for one minute.
Return the engine to idle for five minutes.
Hold the engine speed at 3,000 RPM for one minute.
Run the engine until normal operating temperature is
reached.

30. Switch off the engine and allow to cool.

31. WARNING: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap from the
coolant expansion tank while the system is hot.

Check and top-up the coolant level if required.

cardiagn.com
 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Coolant Expansion Tank
Removal and Installation

Removal

1. WARNINGS:

Release the cooling system pressure by slowly turning the

coolant expansion tank cap a quarter of a turn. Cover the expansion
tank cap with a thick cloth to prevent the possibility of scalding.
Failure to follow this instruction may result in personal injury.

Since injury such as scalding could be caused by escaping

steam or coolant, do not remove the filler cap from the coolant
expansion tank while the system is hot.

CAUTION: Engine coolant will damage the paint finished

surfaces. If spilt, immediately remove the coolant and clean the
area with water.

Release the cooling system pressure.

2. Disconnect the coolant hose.

Clamp the hose to minimize coolant loss.

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Position a container to collect the fluid spillage.
Release the clip.

3. Disconnect the radiator bleed hose.

Release the clip.

4. Remove the coolant expansion tank.

Remove the bolt.
Installation
1. Install the coolant expansion tank.
Tighten the bolt to 10 Nm (7 lb.ft).

2. Connect the radiator bleed hose.

Secure with the clip.

3. Connect the coolant hose.

Secure with the clip.
Remove the hose clamp.

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4. Check and top up the coolant.
Remove the container.
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 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Cooling Fan Shroud
Removal and Installation

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01,
General Procedures).

2. Drain the cooling system.

For additional information, refer to: Cooling System Draining, Filling
and Bleeding (303-03, General Procedures).

3. Remove the cooling fan.

For additional information, refer to: Cooling Fan (303-03, Removal
and Installation).

4. CAUTION: Make sure that all openings are sealed.

Use new blanking caps.

Release the cooling fan shroud.

1. Disconnect the coolant expansion tank hose.
2. Release the coolant expansion tank hose from
the cooling fan shroud.
3. Release the cooling fan shroud remove the 2
screws.

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5. CAUTION: Make sure that all openings are
sealed. Use new blanking caps.

Disconnect the radiator top hose.

6. Release the thermostat from the cooling fan shroud.

7. Remove the cooling fan shroud.

Installation
1. To install, reverse the removal procedure.

2. Connect the battery ground cable.

For additional information, refer to: Battery Connect (414-01,
General Procedures).

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 Published: 05-Dec-2011
Engine Cooling - ID4 2.2L Diesel - Coolant Pump
Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.

1. For additional information, refer to: Battery Disconnect and Connect

(414-01 Battery, Mounting and Cables, General Procedures).

2. For additional information, refer to: Cooling System Draining, Filling

and Bleeding (303-03 Engine Cooling - ID4 2.2L Diesel, General
Procedures).

3. For additional information, refer to: Accessory Drive Belt (303-05

Accessory Drive - ID4 2.2L Diesel, Removal and Installation).

4. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.

Raise the vehicle on a twin-post lift.

5. Torque: 3Nm

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6. CAUTION: Always fit clean plugs to open
connections to prevent contamination.

Bolt torque: 25Nm, Nut torque: 25Nm, Hose clip

torque: 3Nm

7. Torque: 3Nm
 7. Torque: 3Nm

8.

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9. Torque: 23Nm

Installation
1. To install, reverse the removal procedure.

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 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Radiator
Removal and Installation

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01,
General Procedures).

2. Remove the cooling fan shroud.

For additional information, refer to: Cooling Fan Shroud (303-03,
Removal and Installation).

3. Remove the hood latch panel.

For additional information, refer to: Hood Latch Panel (501-27,
Removal and Installation).

4. NOTE: RH shown, LH similar.

Remove the 2 O-rings.

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5. NOTE: RH shown, LH similar.

Remove the 2 charge air cooler brackets.

Remove the 4 bolts.

6. CAUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: RH shown, LH similar.

Disconnect the charge air cooler inlet hose and charge

air cooler outlet hose.

7. CAUTION: Make sure that all openings are sealed.

Use new blanking caps.
 Disconnect the fuel cooler to radiator hose.

8. CAUTION: Make sure that all openings are sealed.

Use new blanking caps.

Disconnect the radiator bottom hose.

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9. CAUTION: Make sure that the radiator and charge
air cooler are not damaged when removed.

Remove the radiator and charge air cooler assembly.

10. Remove the radiator.

Installation
1. To install, reverse the removal procedure.
Tighten to 20 Nm (15 lb.ft).
 2. NOTE: Remove and discard the blanking caps.

NOTE: RH shown, LH similar.

Tighten to 3 Nm (2 lb.ft).

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3. Tighten to 9 Nm (7 lb.ft).

4. Connect the battery ground cable.

For additional information, refer to: Battery Connect (414-01,
General Procedures).
 Published: 11-May-2011
Engine Cooling - ID4 2.2L Diesel - Thermostat
Removal and Installation

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01,
General Procedures).

2. Drain the cooling system.

For additional information, refer to: Cooling System Draining, Filling
and Bleeding (303-03, General Procedures).

3. Remove the cooling fan upper shroud.

Release the 6 clips.

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4. Release the power steering fluid reservoir.
Remove the 2 nuts.

5. Disconnect the charge air cooler outlet hose.

6. NOTE: Cooling fan shroud removed for clarity.

Disconnect the thermostat to radiator top hose.

Release the clip.
 7. NOTE: Cooling fan shroud removed for clarity.

Disconnect the thermostat to coolant pump inlet hose.

Release the clip.

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8. NOTE: Cooling fan shroud removed for clarity.

Remove the thermostat.

Installation
1. To install, reverse the removal procedure.
Tighten to 3 Nm (2 lb.ft).

2. Tighten to 4 Nm (3 lb.ft).
3. Connect the battery ground cable.
For additional information, refer to: Battery Connect (414-01,
General Procedures).

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Content not found

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