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Engine Cooling System
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ENGINE COOLING SYSTEM
CHAPTER 5 ENGINE COOLING SYSTEM
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 RECOMMENDED COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 ENGINE COOLING SYSTEM FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 ENGINE COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 ENGINE COOLING SYSTEM COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . 4.4 COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
ENGINE COOLING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
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WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
WATER PUMP WEEP HOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
THERMOSTAT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 THERMOSTAT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
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RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 COOLANT DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 RADIATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 RADIATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
ENGINE COOLING SYSTEM
GENERAL INFORMATION
Torque Specifications
ITEM Thermostat Cover Alternator Bracket (upper) Alternator Bracket (middle) SIZE 8 mm 8 mm 10 mm TORQUE VALUE 11 ft-lbs (17 Nm) 24 ft-lbs (33 Nm) 33 ft-lbs (45 Nm) 17 ft-lbs (23 Nm) 17 ft-lbs (23 Nm) 8 ft-lbs (11 Nm) 35 in-lbs (4 Nm)
Cooling System Specifications
The engine coolant temperature sensor is located in the water pump housing behind the thermostat cover. Condition Engine Shutdown
(temp. is sustained for 25 seconds)
Approx. 1.22 k ± 2% 1.30 k ± 2%
Temperature 248° F (120° C) 240° F (116° C) 230° F (110° C) 194° F (90° C) 182° F (83° C) 77 °F (25 °C)
Water Pump Mount Bolts 8 mm Engine Temperature Sensor (ECT) Upper Radiator Bracket Mounting Bolt Coolant Hose Clamps 3/8 NPT 6 mm -
Coolant Hot Lamp (On Solid) Cooling Fan On Cooling Fan Off
Room Temperature
Recommended Coolant
Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. Polaris Premium Antifreeze 2871534 - Quart 2871323 - Gallon
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System Capacity
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IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.
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1.45 k ± 2% 2.80 k ± 2% 3.40 k ± 2% 29.9 k ± 2% 13 PSI
Coolant Hot Lamp (Blinking)
Brutus / Brutus HD - 6.6 qts (6.2 L) Brutus HDPTO - 6.9 qts (6.5 L)
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Engine Cooling System Flowchart
Coolant Flow - BRUTUS / BRUTUS HD
ENGINE COOLING SYSTEM TESTING
Engine Cooling System Pressure Test
1. Remove the hood.
WARNING
Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.
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Coolant Flow - BRUTUS HDPTO
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2. Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester. 3. The system must retain 11-14 psi (75-95 kPa) for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, hose clamps and water pump for leakage.
Radiator Cap Pressure Test
1. Remove radiator pressure cap and test using a cooling system pressure tester (commercially available). 2. The radiator cap relief pressure is 13 lbs. Replace cap if it does not meet this specification.
Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.
ENGINE COOLING SYSTEM
ENGINE COOLING SYSTEM
Engine Cooling System Component Locations
Radiator Fan Thermostat Housing
Hydraulic Oil Cooler
Coolant Recovery Bottle Heater Core (inside)
Water Pump
Engine Cooling Fan
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Radiator
Bleed Screw
Coolant Temperature Sensor
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Cooling System Bleeding Procedure
1. Place the vehicle in PARK. 8. Reinstall the radiator pressure cap.
WARNING
Be sure to install the radiator pressure cap before shutting off the engine. Coolant may spit out of the radiator. 9. Stop the engine and allow it to cool. Top off the radiator with coolant. If the coolant level drops indicating that coolant has been pulled into the system, fill the radiator first then fill the recovery bottle. 10. Any air remaining in the system should continue to bleed out through the recovery bottle.
CAUTION
Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap. The coolant may be hot and could cause severe injury or burns. 2. Remove the hood to access the radiator pressure cap and recovery bottle. 3. Remove the pressure cap and top off coolant. Leave the pressure cap off at this point. 4. Remove recovery bottle fill cap and fill the bottle to the "MAX" line. Reinstall the recovery bottle cap. NOTE: If coolant level is very LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the recovery bottle. 5. Start the engine and allow it to idle for 5-10 minutes until the thermostat opens and allows coolant to travel through the entire system. NOTE: When the thermostat opens the radiator coolant level will drop significantly.
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1 2. Carefully straighten any bent radiator fins. 3. Remove any obstructions with compressed air or low pressure water. 7. With engine still idling, top off the radiator with Polaris Premium Antifreeze. If no air bubbles are seen at the radiator filler neck and you only get coolant out of the bleed screw, the system should be purged of air. Washing the vehicle with a high-pressure washer is not recommended and could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended.
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6. Crack the bleed screw (Item 1) on the thermostat housing to release any air from the system. Squeeze coolant lines to help purge the system of air.
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RADIATOR
Radiator Cleaning
11. Repeat this procedure if you are still having difficulty bleeding the system.
1. Check radiator air passages for restrictions or damage on both the radiator and hydraulic cooler.
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ENGINE COOLING SYSTEM
Coolant Drain
1. Remove the hood to access the pressure cap.
Radiator Removal
1. Drain coolant from radiator (see previous procedure). 2. Remove the front fascia (see Chapter 7 - Front Fascia). 3. Remove the four 10 mm screws (Item 2) retaining the upper radiator mount brackets. 3
WARNING
Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool. 2. Slowly remove the pressure cap to relieve any cooling system pressure. 3. Place a suitable drain pan underneath the radiator drain on the left-hand side of the vehicle. 4. Drain coolant by loosening the drain plug (Item 1) until coolant starts to flow out of the valve.
5. Completely drain coolant and properly dispose of it.
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4. Remove recovery bottle return line (Item 3) from the radiator. 5. Remove the lower radiator hose. 6. Remove the three plastic rivets (Item 4) from the air deflectors on both sides of the radiator and remove the deflectors.
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7. Remove the two 10 mm screws (Item 5) retaining the hydraulic oil cooler to the radiator. Lift the hydraulic oil cooler up and towards you to release the lower slotted oil cooler mounts.
Radiator Installation
1. Lift the hood liner and install the radiator into the vehicle. 2. Connect the radiator fan harness (Item 1) and upper radiator hose (Item 2).
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3 NOTE: Be sure the lower grommets or the radiator are positioned properly in the frame upon installation. 3. Install the two bolts (Item 3) retaining the hydraulic oil cooler to the radiator. 4. Install the air deflectors on both sides of the radiator. 5. Install the lower radiator hose. 6. Connect the recovery bottle hose to the radiator. 7. Install the upper radiator mount brackets and torque the fasteners to specification.
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8. Carefully lift up on the hood liner and disconnect the radiator fan motor harness (Item 6) and the upper radiator hose (Item 7). 9. Keep the hood liner up and carefully lift the radiator and fan assembly upward to remove it from the vehicle. 10. Once out of the vehicle, remove the 4 screws that retain the fan and shroud assembly to the radiator.
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Upper Radiator Mount Screws (M6 and T-40 Torx) 8 ft-lbs (11 Nm) 8. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant. 9. Refer to the "Cooling System Bleeding Procedure" in this chapter.
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ENGINE COOLING SYSTEM
WATER PUMP
Water Pump Weep Hole
The water pump weep hole is located on the housing underneath the water pump belt pulley. If there is coolant leaking out of this hole, the mechanical seal is damaged and the water pump assembly would need to be replaced. 4. Loosen the alternator mount adjuster one turn, pull the alternator towards the engine to get slack in the belt and remove the belt from the water pump pulley. 5. Remove the four bolts (Item 2) retaining the engine fan / water pump pulley assembly and remove the assembly from the engine.
Water Pump Removal
NOTE: The water pump impeller, mechanical seal, pump shaft, and pump shaft bearing are not serviceable components. If one of these components fails, the water pump assembly must be replaced. 1. Disconnect the battery.
6. Remove the coolant hoses (Item 3) going to the water pump.
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2. Drain coolant from the radiator (see Coolant Drain earlier in this chapter) and put a catch pan under the vehicle below the water pump assembly.
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3. Remove the three screws (Item 1) retaining the engine fan guard.
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7. Disconnect the engine temperature sensor (Item 4). 8. Remove the two bolts (Item 5) retaining the alternator bracket to the engine. 9. Pivot the alternator bracket towards the front of the vehicle to gain access to the hidden water pump mounting bolt. (you may need to slightly loosen the A/C compressor mount to get the bracket to pivot)
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10. Remove three bolts (Item 6) retaining the water pump to the engine. 6
Water Pump Installation
1. Install thermostat and thermostat cover. Torque bolts to specification 2. Clean the water pump to engine block mating surface. 3. Install water pump assembly and torque the three mounting bolts to specification. 4. Pivot the alternator bracket back towards the engine. Install the top bolt first by hand. Install middle bracket bolt and torque to specification then torque middle bolt to specification. 5. Connect the engine coolant temperature sensor and the coolant hoses going to the water pump.
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11. Remove water pump assembly. 12. Remove the two thermostat cover bolts and remove the cover and the thermostat.
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9. Connect the battery.
NOTE: On units with a heater system, there will be three hoses off the water pump instead of two. 6. Install the fan, spacer and pulley onto the water pump assembly. Torque the four bolts to specification. 7. Install the belt onto the waterpump, engine, and alternator pulleys. Properly set the tension on the alternator belt (see Chapter 2 - "Alternator / Fan / Water Pump Drive Belt"). Torque adjuster bolt to specification. 8. Install the engine fan guard. Torque the three screws to specification.
10. Top off the coolant in the radiator and recovery bottle and perform the "Cooling System Bleeding" procedure.
Thermostat Cover Bolts: 11 ft-lbs (17 Nm) Water Pump Mounting Bolts: 17 ft-lbs (23 Nm) Alternator Bracket Bolts: M8 (upper): 17 ft-lbs (23 Nm) M10 (middle): 35 ft-lbs (47 Nm) Engine Fan / Water Pump Pulley Bolts: 11 ft-lbs (17 Nm) Engine Fan Guard Screws: 8 ft-lbs (11 Nm)
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ENGINE COOLING SYSTEM
THERMOSTAT
Thermostat Removal
1. Drain coolant so the coolant level is below the thermostat housing (see "Coolant Drain / Radiator Removal"). 2. Tilt the cargo box so it is in the fully open position. 3. Remove the two bolts (Item 1) retaining the thermostat cover. Long Bolt
Thermostat Installation
1. Clean the mating surfaces on the thermostat cover and the water pump assembly to assure a good seal. 2. Install the thermostat, thermostat cover, and two bolts. Torque bolts to specification.
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4. Lightly pry on the thermostat to remove the thermostat from the engine.
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NOTE: Do NOT pry between the thermostat and the water pump housing or damage to the sealing surface will occur.
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3. Top off the coolant in the radiator and recovery bottle and perform the "Cooling System Bleeding" procedure.
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Thermostat Cover Bolts: 11 ft-lbs (17 Nm)
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TROUBLESHOOTING
Cooling System
Overheating · Low coolant level · Air in cooling system · Wrong type/mix of coolant · Faulty pressure cap or system leaks · Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage) · Engine running lean (fuel system restriction) · Fuel pump output weak · Water pump failure/ Loose impeller · Engine Coolant Temperature Sensor failure · Electrical malfunction · Cooling fan inoperative or turning too slowly · Low oil level · Faulty hot lamp circuit · Thermostat completely stuck closed
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not opening
Temperature Too Low · Thermostat stuck open
Leak at Water Pump Weep Hole
· Worn pump shaft or pump shaft bearing
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· Faulty water pump mechanical seal
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ENGINE COOLING SYSTEM
NOTES
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