Chapter 10 Cooling System

Section 1 Composition & Features of Cooling System

High temperature (above 2200°C) caused by the running of engine will heat up the contacted parts (like cylinder head,
cylinder block, piston, piston ring, valve, etc) , thus reduce the mechanical strength of the above parts, cause distortion,
damage the normal clearance between parts, cause serious weariness, or even serious dislocation and cracks. High
temperature will also cause malfunction of lubrication oil, which will lower the co efficiency of air inlet and reduce engine
power. Adequate cooling to parts working under high temperatureconditions is an essential process to ensure the proper
function of the engine. However, it is important to
make adequate cooling. If being under-cooled,
malfunctions like reduction of inlet air volume, incom-

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plete combustion, inflammation caused by knock, Water pump
surface inflammation, etc will occur. If being
overcooled, work temperature of lubrication oil will be
lowered, which will increase the vicosiity of lubricant.
The increase of lubricant viscosity will increase friction Cylinder

A/c radiator
body cover
to the contacted moving parts. Besides, the redundant
heat emitted by the running of engine will result in
Radlator

Outer cycle
condensation of vapor in the heated air and increase Lnner cycle
Cylinder
acidity of air, both of which will add corrosion to the head cover
cylinder. Also, the condensed gasoline vapor will
result in backflow of gasoline oil drop to the lubricant
sump, which will hazard the economy and power of
Ldle speed
engine, increase the weariness and shorten its effec- valve cover
tive life.
Cooling system is designed to ensure adequate
cooling and working temperature for engine under any
Thermostat
possible working conditions. The diagram for the
circulated working process of cooling system is shown
on 316. Fig. 316 Cycling Route of Coolant

Closed forced water cooling system is chosen for engine. The system is composed of a radiator (water tank), a water pump,
a thermostat electric fan, a temperature controller and cooling pipes, etc.

1. Structure & Features of radiator

MR6370 radiator belongs to tube and strap type. The structure is characterized by high radiation efficiency, light-weight,
easiness to manufacture, etc. The size of heat radiator adopted by MR479Q engine is shown on Table 16.

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Table 16 Specification of MR6370
Item MR479Q engine

Water capacity of radiator (L) 5.3 (total volume of coolant, 0.9 of which is
the capacity of radiator)

Radiation efficiency (kJ/h) 158 (when the fan power is 1kw)

Radiation area (m2) 5.5

Size of the radiator core (W X H X T) (mm) 388 x 350 x 32

II. Structure & Features of Water Pump

The water pump of engine is a centrifugal vane one. The pump pressurizes the coolant and makes coolant circulatied in
line of the system design.
The pump body is made of aluminum alloy, aimed to be more corrosion-proof. The pump is driven by belt connected with
crankshaft pulley. The size of pump is shown on Table 17.

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Table 17 Specification of water pump
Model Centrifugal

Output volume (L/min) 100 (pump speed 3000r/min)

Vane diameter (mm) 60

The pump is composed of pulley seat, bearing, pump body, water-seal compo, rotor, gasket, cover of suction port (Fig.
317), etc.
Water-sead compo

Pump body

Bearing

Cover of intake valve

Gacket
Rotor

pullry Fig. 317 Pump Assy.

III. Structure & Features of thermostat

Engine adopts wax-type single valve thermostat. Its size is shown on Table18, while its structure is shown on Fig. 318 and
319.
The thermostat is located inside the body of water intake end, interconnected with cylinder’s jacket. The upper end of rod
4 is fixed on support 3, while its lower end is inserted into rubber boot 5. Both rubber sheet 5 and body1 is filled with wax
7. If coolant temperature is lower than 80°C, wax will be solidified and valve 6 will be pressed to close via spring 2.Thus
coolant will directly flow into cylinder’s cooling jacket via bypass valve 10

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 Table 18
Specification of Thermostat
Model of thermostat Wax type

Temperature in °C (valve begins to opened) 82±2

Temperature in °C (valve fully opened) 95

Valve lift stroke mm 8

without passing through radiator. The above process is called a small circulation, with limited magnitude. If coolant
temperature is higher than 80°C, wax 7 will be liquefied. Thus, its expansion will force the rubber boot 5 to contract. As
upper side of rod 4 is fixed, the contraction of rubber boot 5 will push housing 1 to overcome the pressure of spring 2 and
move downward and push open valve 8. The opening of valve 8 will allow most coolant to pass through heat radiator, thus
the so-called large circulation is completed. However, in the case of large circulation, there is still a small amount of coolant
to bypass through. It is of great magnitude.

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Water inlet seat Sealant gasket
Double-start stud M8x45

Water inlet

Thermostat
Double-start stud M6x25

Cooling water Double-start stud

bypass hose joint M8x45
Minor cycle water Binding bolt
inlet joint Double-start stud M6x25
All metal hexagonal flange lock nut
Thermostat sub assembly

Water temperature sensor

Fig. 318 Installation of thermostat

a) b) c)
Fig. 319 Wax single Valve thermostat
1. Housing 2. Spring 3. Bracket 4. Push rod 5. Rubber boot 6. Valve (closed) 7. Wax 8. Valve (opened) 9. Fixed flange 10. Bypass

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 IV. Temp.control electric fan

Specification of electric cooling fan is shown as Table 19, while components are shown as Fig 320.

Table 19 Specification of electric cooling fan

Engine model MR479Q engine
Item

Model DC motor

Direction of rotation Clockwise (from driver cab)

Output power (W) 60

Current (A) 6.7±1

Fan model Suction type fan

Fan Fan cover Fan Motor

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Fig. 320 Electric cooling fan components

The fan of SMA series M1.5.4 coolant fan is controlled by ECU according to the signal of water temperature sensor on the
inlet water seat and temperature detect switch mounted on the water inlet .ECU receive the signal of water temperature,
The fan low shift works at 92.5°C, and will be shut off at 90.7°C.The cut on/off of temperature detect switch depends on
coolant temperature. When the coolant temperature is higher than 101°C±3°C,temperature detect switch cuts on, fan
motor works and fan high shift rotates. If coolant temperature is lower than 95°C±2°C,temperature detect switch cuts off ,fan
high shift stops working. The technical parameters are shown in Table 20. With regard to the M7.9.7 EFI system in
JL481Q/MR481QA car, the basic principle of the rotation and operation of its cooling fan is as follows: The water sensor
transmit the temperature signal to ECU,ECU control the operation and cut on/off of fan high/low shift

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 Table 20
Radiator temperature detect switch

type Wax type

Cut on temperature 101±2

Cut off temperature 95±2

Color mark black

Section 2 Inspection and Maintenance of Cooling System

1. Cleaning and Maintenance of Radiator
Clean the radiator with compressed air or water. Make sure fan motor is not moistened. (Better offer protection to the

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motor)
1. Inspect whether there are any injuries on the external surface of the radiator. Replace-
ment may be considered if the injury is serious.
Inspect the interior quality. Turn off the cap of heat radiator, fill coolant into cooling system, turn on the cap and install the
pressure inspector (Fig. 321).
2. The pressure inspector will inspect the leakage of system under pressure of
117.6kpa,including leakage in radiator, leakage in water pump, leakage in hoses, and over-
expansion of hoses, etc. Any leakage will be welded. If the welded parts still fail to meet the
requirement, the parts shall be replaced.
3. Inspection on water filling port (Fig. 322)
Flat sealing surface

Deformed rim

Fig. 321 Pressurize to the cooling system Fig. 322 Inspection of deformation of water filling port

(1) Inspect whether there are any deformation on the sealing surface. If any defects are found, the parts shall be repaired
or replaced.
(2) Inspect the edge part of parts. If any defects are found, such parts shall be repaired.
4. Inspection on radiator cover
(1) Inspect the sealing gasket (see Fig. 323). If bent or deformation is found, the gasket shall be replaced.
(2) Inspect air valve and seat. If deformation or notch is found, such parts shall be replaced.
(3) Inspect the water scale between air valve and valve seat. Clean all the water scale if found.
(4) Inspect the working condition of sealing pressure and vacuum safety valve seat (Fig. 324).

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The upper limit for air valve’s opening pressure is 58.5kPa, while standard value is 73.5-102.9kpa. If malfunction is found,
such valve shall be replaced.

Deformation and defect

Bending or defomation of valve or valve seat
of sealing gasket
Water rust
between valve
and valve seat

Fig. 323 Inspection of radiator cap Fig. 324 Inspection of sealing pressure

II. Inspection & Maintenance of Water Pump

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Detach the water pump pulley, pump bearing, impellor and sealing parts with dedicated tools.
Inspect the water pump in the following sequences.
1. Inspect the water pump impellor. pump body If any damage, abrasion and crack are found, the
parts shall be replaced.
2. Inspect the water pump shaft, make sure no damage and no abnormal noise occur in rotation.
3. Inspect sealing components. If any defects are found, the parts shall be replaced.
4. Inspect the O-ring for pump connecting pipes. If signs of aging and damage are found, the
parts shall be replaced.

III. Inspection on Thermostat

Submerge the thermostat in the water. Heat the water up in a gradual manner. Inspect the valve opening temperature as
indicated on the thermostat᷉see Fig.325᷊

Valve eift

Fig. 325 Inspection of open/close temperatures and valve lift of thermostat valve

The valve opening temperature is within the range between 80°C-84°C(1.3L/1.5L) and 78°C-80°C(1.6L/1.8L) ,while valve
lift is higher than 8mm (at the temperature of 95°C). If the temperature does not meet the above requirements, replace the
thermostat. If deformation is found, repair shall be done using dedicated tools. If temperature is lower than 40°C, inspect
whether the valve is opened or not. If the valve is not closed completely, it shall be replaced.

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 IV. Inspection & maintenance on temperature-controlled electric fan

Connect positive pole and negative pole of electric fan to positive Ampere meter
pole and negative pole of the battery .Electric fan shall be able to
rotate freely after the fan motor was connected with the battery.
Inspect the electric current with ampere meter᷉5.7-7.7A,see Fig
326᷊. If motor fails to rotate correctly, inspect the welding points
on the circuit. If it is still out of order after troubleshooting on
connection, the electric fan shall be replaced.

storage battery
Fig. 326 Inspect the fan current value and its rotation

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V. Water filling and Air Exhaust

If coolant level falls below “low” mark, open the cover of water tank and replenish running water slowly to a level between
marks of “full” and “low” when the water tank is cold. If the replenishment occurs when water tank is in hot status, slowly
open water tank cover and replenish running water slowly to a level between marks of “full” and “low with wet cloth. Air
exhaust from water tank is usually an automatic process, and repair is required if any failure occurs.

Section 3 Malfunction and Trouble shooting of Cooling System

Most troubles come from the following three:

1. Engine overheat caused by under-cooling

If under-cooled, parts like cylinder and cylinder head will be over-heated. Thus, replenishment of coolant is needed.

II. Adequately cooled but engine is overheated

If engine is overheated when coolant volume is adequate, it is possibly caused by pump failure, loose pump belt, fan failure
or thermostat failure, etc. Adequate trouble shooting measures are required.

III. Abrupt overheat

Abrupt overheat may be caused by sudden belt rupture, or bearing failure that disables the coolant pump. Thus, replace-
ment of belt and bearing is required. Other possible causes may be fan failure caused by fuse melting or electric failure that
disables the fan. Thus, replacement of fuse or repair of motor is required.

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