Defender. Manual — part 108
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12
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Cooling fan lower cowl
13
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Radiator bottom hose
14
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Thermostat assembly
15
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Intercooler
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 and cooling for the Exhaust Gas Recirculation (EGR) system.
The cooling system comprises:
A radiator
A passenger compartment heater matrix
An EGR cooler
A coolant pump
An expansion tank
A cooling fan
Connecting hoses and pipes
The coolant is circulated by a centrifugal type pump mounted on the front Left Hand (LH) side of the engine and driven
by the ancillary drive 'polyvee' belt. The coolant pump circulates coolant around the cylinder block and cylinder head, to
the radiator, heater matrix and the EGR cooler, via the coolant hoses.
The thermostat is located in the bottom hose assembly on the inlet side of the cooling circuit and provides a stable
control of the coolant temperature in the engine.
The radiator is a cross flow type with an aluminium matrix and moulded plastic end tanks. The radiator end tanks have
brackets which allow for the attachment of the fan cowl assembly, intercooler and, if fitted, air conditioning system
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.
An air-to-air intercooler is located in front of the radiator and is used to cool the compressed air from the turbocharger
before it enters the inlet side of the engine.
For additional information, refer to:
Intake Air Distribution and Filtering
(303-12 Intake Air Distribution and Filtering -
2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Description and Operation).
The radiator top hose is connected to a coolant outlet elbow, which is bolted to the cylinder head. The top hose also has
a connection for the feed to the heater matrix. The radiator bottom hose is routed around the front of the engine and is
connected to the thermostat assembly. The bottom hose also has a return connection from the fuel cooler. The feed for
the fuel cooler comes from a connection just below the bottom hose connection on the Right Hand (RH) side of the
radiator assembly.
An 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 replaces the coolant into the system as the engine cools down.
The EGR cooler is located in the coolant return line from the engine and top hose. The fluid cools the exhaust gases
returning to the inlet manifold, which improves emissions.
The heater matrix outlet hose incorporates a bleed screw to bleed air when filling the cooling system.
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Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Engine Cooling
Diagnosis and Testing
Overview
For information on the operation of the systems:
REFER to:
Engine Cooling
(303-03 Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Description and
Operation).
Inspection and Verification
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious mechanical or electrical faults.
Visual Inspection Chart
Mechanical
Electrical
Coolant leaks
Coolant hoses
Coolant expansion tank
Radiator
Heater core
Accessory drive belt
Viscous fan
Fuses
- Fuse 29, passenger compartment
Harnesses
Loose or corroded connector(s)
Cylinder head temperature (CHT) sensor
Engine oil temperature (EOT) sensor
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. 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
Gaskets
Engine casting
cracks
Engine block core
plugs
Carry out a visual inspection. If there are no obvious leaks, carry out a pressure
test using your workshop tester. Rectify as necessary.
Overheating
Low/contaminated
coolant
Thermostat
Viscous fan
Cylinder head
temperature
(CHT) sensor
Restricted air flow
over the radiator
Check the coolant level and condition. Carry out a pressure test using your
workshop tester. Rectify as necessary. Check the thermostat and rectify as
necessary. Check the viscous fan operation, make sure the viscous fan rotates
freely. Check for obstructions to the air flow over the radiator. Rectify as
necessary.
Engine not
reaching
normal
temperature
Thermostat
Viscous fan
Electric fan
Check the thermostat operation. Check the viscous fan operation, make sure the
viscous fan is not seized. Rectify as necessary.
DTC Index
• NOTE: If a control module or component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval program is in operation,
before the replacement of a component.
• NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).
• NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal
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places, and with an up-to-date calibration certificate. When testing resistance always take the resistance of the DMM
leads into account.
• NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
• NOTE: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
• NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern
may be the cause. Always check for loose connections and corroded terminals.
• NOTE: For a full list of engine control module (ECM) DTCs:
REFER to:
Electronic Engine Controls
(303-14 Electronic Engine Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Diagnosis and Testing).
DTC
Description
Possible causes
Action
P01152F Engine coolant temperature (ECT)
(cylinder head temperature (CHT))
sensor 1 circuit - signal erratic
CHT
sensor
circuit:
short
circuit to
power
CHT
sensor
circuit:
short
circuit to
ground
CHT
sensor
circuit:
open
circuit
CHT
sensor
fault
Check the CHT sensor and circuit. Refer to the
electrical guides. Install a new CHT sensor if
necessary.
REFER to:
Cylinder Head Temperature (CHT) Sensor
(303-14 Electronic Engine Controls - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, Removal and
Installation).
Clear the DTCs and test for normal operation.
P011516 Engine coolant temperature (ECT)
(cylinder head temperature (CHT))
sensor 1 circuit - circuit voltage below
threshold
CHT
sensor
circuit:
short
circuit to
ground
CHT
sensor
circuit:
open
circuit
CHT
sensor
fault
P011517 Engine coolant temperature (ECT)
(cylinder head temperature (CHT))
sensor 1 circuit - circuit voltage
above threshold
CHT
sensor
circuit:
short
circuit to
power
CHT
sensor
fault
P048000 Fan 1 control circuit on/off
Cooling
fan control
circuit:
short
circuit to
ground
Cooling
fan control
circuit:
short
circuit to
power
Cooling
fan control
circuit:
Check the cooling fan and circuits. Refer to the
electrical guides. Install a new cooling fan if
necessary.
REFER to:
Cooling Fan
(303-03 Engine Cooling - 2.4L
Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Removal and Installation).
Clear the DTCs and test for normal operation.
open
circuit
Cooling
fan fault
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