1B69 ——-AAN SECTION 1B ENGINE COOLING SYSTEM GENERAL DESCRIPTION 18—70 TROUBLESHOOTING 1B—74 INSPECTION & MAINTENANCE ‘ 1B—74 Coolant 1B 74 Coolant Level 1B—75 Cooling System Service 1B—76 Cooling System, Flush and Refill 1B—76 ON-CAR SERVICE 1B—77 Coolant Draining “1B—77 Coolant Pipes or Hoses 1B—77 Thermostat 1B—77 Radiator 1B—79 Water Pump 1B—791B-70 GENERAL DESCRIPTION COOLANT CIRCULATION The cooling system consists of he water pump, radiator, thermostat, coolingtan, rubber hoses, anditmakes theengine cooled to protect the overheating and to maintan the adequate temperature of the engine Resenoir tank Radiator cap 7 Heated Cooled 4 Radiator Radiator a 7 @) (0) FIG, 1B—2 ‘The seal end pressure type radiator getsa structure to sealle radiator with aradiator cap, andio receive theexpene™t flows in the reservoir to prevent the expanded coolant from flowing outside Fig.(a) shows the coolants heated and expends and that the expended portion ofthe coolant flows fram the radial Into the reservoir tank, As the pressurein the cooling system s over a specified level, the pressure valve of 12d! ‘cap is to be open to flow the heated coclant into the reservoir tank through avertiow pips. Fig.(b) shows the Contracts as the coolant temperature is lowered. At this time the pressure falls and the vacuum valve of radial is to be open to draw the reserved coolant ack into the radiator by the pressure difference1B-72 Radiator Cap ‘A pressure-vent cap is used on the radiator. The cap contans pressure valveandvacuumvalve Thepressure valveisheldagainstits seatby a spring of pre-determined ssrength which protects the cooing system by relieving the pressure automatically. if the pressure in cooling system rises by 0.9kglet ‘The vacuum valve 1s neld against its seat by a light pring which parmits opening ofthe valve to relieve the negative pressure crested in the system when it cools if and which otherwise might cause the radiator to collapse. The cap has its face marked 9 which means that is pressure valve opens at 0. Skat 1. Pressure vaive 2. Vacuum valve 4. Procoure relic! 6. From reservoir tank 4. To resorvoir tank 5. Vacuum retet FIG. 1B —6 A PRESSURE VENT TYPE RADIATOR CAP Coolant Reservoir Tank ‘A reservoir tank is connected to the radiator by a hose. ‘As the cari driven, the coolantis heated and expands. ‘The portion of coolant expanded by heatflows from the Tadiaior into the reservoir tank through the hose. When the car is stopped, the coolant contracis and the isplaced coolantis drawn back into the radiator by the pressure difference. Thus, the radiator iskeptfilled with coolant to the desired level at all time, resulting in increased cooling efficiency. Water Pump The cantrlugal type water pump is used in the coaling system. The pump impeller is supported by a totally sealed bearing disassembled The water pump can no! be | 1. Weter pump | 2. Timing belt ie 3. Weter pump pulley FIG. 18 —6 WATER PUMPThermostat Awaxpallet type ihermostatis used in the coolartoutet Passage to control the flow of engine coolant, and to regulate coolant temperature. Awax pallet elementis contained in a metel caso, and ‘expands when heated and contracts when cooled. When the pallet is heated and expends, the metal case Pushes down the valve to open it AAs the pallet is cooled, the contraction allows a spring toclose the valve. Thus, the valve remains closed while the coolant is cold, preventing citculation of coolant through the radiator, At this point, coolent is allowed io sirculate only throughout the engine to warm it quickly and everly. As the engine warms, the pallet expands and the thermostat valve opens, permiting coolant to Yow through the radiator. In the top porion of the hermostat, an airbleed valve is provided. This valveis ‘or venting out the gas or ar, ifeny, that is accumulate nthe circuit Air bleed valve FIG. 18 —7 THERMOSTAT Themostlfunctonal spec(+1 5t) Temperature at which valve Begins 1o pani ) Be poe ee e, Temperature ai which valve become fully open tc) oe | es H Nave it mer than 8 at 95 Bere tiny ero an a 95 L Open FIG. 1B — 8 OPERATING THERMOSTAT lEngine side) Thermostat (1) Whe to open (2) Whe FIG. 1B —9 OPERATING AIR BLEED VALVE18-74 TROUBLESHOOTING [ Condition | Probable Cause Correction (nee ase Sea [Sams cammie enous + Malfunction of thermostat + Replace + Maltunction of water pump | + Replace + Clogged ratiator pin + Gean or repair + Leakage of coolant | «Repair + Damage of cooing fan switch + Check and replace it necessary + Clogged ratiator | + Repiace + Malagjustrent of ignition tiring + Adjust + Maffunction of radiator cap + Replace + Dragging brake + Adust | Stpping tach + Adjust or replace INSPECTION AND MAINTENANCE COOLANT The coolant recovery systemis standard, The coolant in the radiator oxpands with heat, and tho overflow is collacted in he resenvoirtank. When the system cools. down, the coolant is drawn back ito the radiator. The mixing rate ofthe antifreeze depends upon the lonest ambien temperature of the area CAUTION Besides the antifreezing effect, the coolant | works excellently as an anti-corrosion and a foam-inhibited coolant. And for the pertorm- | spesotooctantkaapthe specteceoncentatin |_ 8 noted in below table. | Lowest Tegel | Wensctnue | Below 14st) 260] orm | 650 | Concentration] 30% | 40% | 50% | earDLANT LEVEL heck level, lift hood and look at the reservoir tank Not necessary 10 remave radiator cap to check intlevel \UTION | not remove reservoir tank cap while coolant | boiling, | 1 engine is cool, check coolant level in reservoir ‘Anormal coolantlevel should be between "FULL" "LOW" marks on reservoir tank slant level is bolow "LOW" mark, romove reservoir cap and edd proper coolantto tank to bring coolant up to "FULL" mark. UTION if proper quality antifreeze is used, it is not necessary toaddextra inhibitors or adaitives | that claim to improve system. They may be armful to proper operation of system. Keep the arrow marks on the tank and cap in ine to put the cap on the reservoir tank. Maximum Minirmum 3.18 — 10 CHECKING COOLANT LEVEL 1B-75 Coolant Capacity Capacity!) | Resenoirtenk1B-76 COOLING SYSTEM SERVICE Cooling system should be serviced as follows. 4. Check cooling system for leaks or damage. 2. Wash radatorcap and llerneckwithclean weterby removing radiator cap when engine is cold. 3. Check coolant for proper level and freeze protection 4. Using pressufe tester, check systom and radiator cap for proper pressure holding capacity 0.9kgfar. If replacement of cap is required, use proper cap spectiad for this vehicle. 5. Tightenhose clamps andinspectall hoses. Replace hose whenever cracked, swollen or otherwise ceterorated 6. Clean frontal area of radiator core CAUTION When installingradiatorcap, make sure the ears be lined up with reservoir tank hose. 2. Ear 3, Rasenoirtank rose 1, Radatorcap FIG. 1B-—11 RADIATOR CAP COOLING SYSTEM, FLUSH AND REFILL 1. Remove radiator cap when engineis cool. Turfithe cap to left slowly until all the pressure loss is confirmed{unti no "HUE" sound is made), end pressing the cap down, tur itagan toleftt take it oft | CAUTION | To avoid the personal injury do not remove | radiator cap while engine and radiator are still | hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon. 2. With the radiatorcap taken of, runthe engine inidlo Until the upper radiator hose become ho! by the Coolant flowing through the thermostat opened 3. Stop the engine, and disconnect the lowerradiator hose to drain the coolant 4. Reinstall te lower radiator hose and fil the systam with water. Then run engine in ie until the upper radiator hose is hot. 5. Repeat these procedures 3 or 4 times until the drawing coolant almost becomes colariese. 6. Scrub and clean inside of reservoir with soap end water. Flush it wel with clean water and drain Reinstall tank and hose. 7. Add 50% mixture antifreeze and water to radiator and reservoir tank(iling radiator to the base of radiator filer neck ard reservoir tank to"FULL"level mark), After filing, make reservoircaplinedup with the arrow mark on the tank | 8. Runengine, with radiatorcap removed, unti radiator upper hose is hot 9, With engine idling, add coolant to radiator untlevel reaches to bottom offilerneck. Install radiator ca, ‘mekingsure thatthe earafcaplines up withreserv@t tank hese.1B-77 ON-CAR SERVICE | CAUTION Before disassembling the cooling system, check to make sure the cooling water temperature is cold,andbesuretodisconnect © terminal from battery. COOLANT DRAINING 4. Remove radiator cap. 2. Disconnect the radiator lower hose and drain the coolant. 98. After draining coslant, install the lower hose and tighten well the clamp. 4, Seepage 75 to refill the coolant COOLANT PIPES OR HOSES Removal 1. Drain the coolant 2. To remove these pipes or hoses. Loosen screw on ‘each pipe or hose clamp end pull hase end off. Installation Itis the reverse of removal procedures. Take care of the foliowings. : * Tighten enough each clamp bolts * Soo page 75 to refil the specified coolant. THERMOSTAT Removal 1. Drain the coclant Disconnect thermostalcapfromthermostathousing Which is installed between dstrbutor case and intake manifold. 1. Dstnibtor case 2. Thermostat housing 3. Thermostat levy FIG. 18 — 12 REMOVING THERMOSTAT1B-78 Inspection 4. Make sure that air bleed valve of thermostat is clear(it valve is clogged, engine would tend to overheat). Air bleed valve FIG, 18 — 13 AIR BLEED VALVE OF THERMOSTAT 2. Check valve seal for some foreign materials being ‘stuck which prevent from secure seating, 9. Checkthermostaimovementolwaxpalletasfollows, + Immerse thermostat in water, and heat water ‘gradually, + Check that valve starts to open at specttied temperature. + If valve starts to open at a temperature substantially below or above specified tomperature, thermostat unit shouldbe replaced with new one, because such a unit will bring about overcoaiing or overheating tendency. Thermostat Theemometer 3. Heat FIG. 1B — 14 INSPECTION OF THERMOSTAT VALVE OPERATION Installation 4. Insiall thermostat in the thermostat housing with the air bleed valve in the front side ot engine. 2. Install anew gasket on the thermostat housing 3. Rell the coolant |1B-79 RADIATOR Removal 1, Discornect © terminal from batiery. 2. Disconnectthe lowerhose of adictor, and drainthe coolant, 3. Disconnect coupler of cooling fan motor lead wire. 4. Remove coolant hoses fom radiator. 5. Remove the radiator. Inspection (Checkradiatorfor any leakage or damage and straighten the flattened or bent pins, if any. Clean Clean front of the radiator cores, FIG. 1B —15 CLEANING RADIATOR _Mstallation Nis the reverso of romoval procedures CAUTION > See page 74"COOLANT"to rofill the coolant _In the system, (Check each joints for ary leakage. | WATER PUMP Removal Disconnect © terminal from battery. Drain the coalan. Remove crankshaft pulley. Remove timing belt outside cover, eer FIG. 1B — 16 TIMING BELT OUTSIDE COVER 5, Remove tensioner and timing bolt, 4, Tensioner l 2. Tensioner bolt FIG. 18171B-80 6. Water pump 4. Wate’ pump 2. Timing bot 3. Water pump pulley FIG, 18 — 18 WATER PUMP PULLEY Inspection CAUTION Do not disassemble water pump, Many repair is required on pump, replace it with new one. | Rotate weter pump by hand to check for smooth opera: tion. lf pump does not rotate smoothly or makes an abnormal noise, replace it FIG. 18 — 19 CHECKING WATER PUMP. Installation 1. Install the new pump gasket on oylincey block 2. Install water pump on cyinder block TTightering torque | | forbolts and nuts(kg+my | 1° 10 8. Install bolt tensioner, timing belt, timing belt outside cover. | CAUTION ‘+ Special care must be required when installing betttensioner and timing belt. Be sureto refer to page 33 of this manual. [ + Tighten each bolt and nut to specified torque, 4 Connect © terminal at battery. 5. Rell the coolant 6. Aftor installing, check each part for any toskage.