Engine Cooling System Engine

Engine Cooling System

Specifications
Torque
Description Value
Screw - Expansion Tank Assembly Tightening 5.5–7.5 Nm
Screw - Cooling Fan Assembly Tightening 5.5–7.5 Nm
Screw - Governor Resistor Tightening 5.5–7.5 Nm
Screw - Air Conditioner Condenser Tightening 5.5–7.5 Nm
Bolt - Oil Cooling Pipe to Oil Cooler 35-40 Nm
Screw - Main Oil Cooler Assembly Bracket to Automatic 7–10 Nm
Transmission Case
Bolt - Thermostat Housing Assembly to Cylinder Head 8–12 Nm
Bolt - Water Pump to Cylinder Block 8–12 Nm
Bolt - Water Pump Pulley to Pulley Hub 9–11 Nm

Parameter

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Coolant Volume: 7.3 L
Cooling Fan: Temperature Control Power Axial-Flow Type
Switch Point of the Cooling Fan - For the air
conditioner System
High Speed:
1.77 Mpa
• ON
1.37 Mpa
• OFF
Switch Point of the Cooling Fan - For cooling when the
engine runs normally
ON:
100 ℃
• Low Speed
112 ℃
• High Speed
OFF:
94 ℃
• Low Speed
106 ℃
• High Speed
Switch Point of the Cooling Fan - For cooling after the
engine stops
ON:
110 ℃
• Low Speed
104 ℃
• High Speed
OFF:
106 ℃
• Low Speed
100 ℃
• High Speed
30 s at most
Duration
Radiator Straight Flow Type
Cooling Water Pump Mechanical, Radial-Flow Impeller

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Drive Ratio of the Cooling Water Pump 1: 1

Double Thermostat Wax-Type Element
Primary Thermostat:
• Originally Open 80±2 ℃
• Completely Open 92 ℃
• Close
≤80±2 ℃
Secondary Thermostat:
• Originally Open
88±2 ℃
• Completely Open
102 ℃
• Close
≤88±2 ℃
The Relief Valve of the Tank Pressure Cover
• High-Voltage Open 93-123 KPa
• Low-Voltage Open 0-9.8 KPa

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Engine Cooling System Engine
Description and Operation
System Component Layout
Cooling Module and Hose

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A = Heater Core Water Inlet; B = Heater Core Water Outlet
1. Cooling Module Seal Sponge 9. Cooling Module Seal Sponge
2. Radiator 10. Expansion Tank
3. Radiator Water Hose Inlet 11. Radiator Water Hose Outlet
4. Cooling Fan Assembly 12. Cooling Fan Motor
5. Expansion Tank Cover 13. Oil Cooler Water Hose Inlet
6. Radiator Pressure Seal Cover 14. Heater Core Water Hose Outlet
7. Radiator Cushion Plate 15. Heater Core Water Hose Inlet
8. Radiator Overflow Hose 16. Cooling Fan Low Speed Resistor

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Water Pump and Thermostat

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1. Water Pump 3. Water Pipe
2. Thermostat Assembly

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Engine Cooling System
Description
General Description
Coolant cycles in the engine, radiator and heater core circuit.
It is a mixture of 50% water and 50% organic acid technique
(OAT), in order to keep the engine at optimum operating
temperature in different environment and engine operating
conditions.
Caution: The engine coolant damages the painted
surface. If the coolant overflows, immediately clean it off
and wash with water.
Periodic replace the coolant to maintain the optimal efficiency
and anti-corrosion performance.
Cooling System Components
Coolant Pump
Coolant is circulated by driving the coolant pump, which is
fitted on the upper rear part of the engine crankcase drive
end, sealed on the cylinder block with an O-ring and driven by
the camshaft timing pulley.
Coolant Hose
The coolant hose connects each component of the cooling
system and the coolant runs among each component through
the coolant hose. The coolant hose is secured on each
component with spring clamp.
Radiator Pressure Seal Cover
The radiator pressure seal cover is fitted on the top of the
radiator, and the pressure limiting valve and the vacuum valve
are on the pressure seal cover. When the system pressure
reaches 93-123 kPa, the pressure limiting valve opens to
discharge the system pressure; when the system pressure
reaches 0-9.8 kPa, the vacuum valve opens to allow the outside
to fill the system with fluid. Thus, the cooling system runs in
a certain pressure range.
Expansion Tank
The expansion tank is fitted on the right of the cooling module
cooling fan, with an overflow/return hose connected from the
bottom of the expansion tank to the top of the radiator. When
the coolant expands after being warmed up, the extra coolant
in the cooling system runs back to the expansion tank through
the overflow/return hose; when the coolant in the cooling
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system is insufficient, the coolant in the expansion tank returns
to the cooling system through the overflow/return hose.
Thermostat
The thermostat is a wax-type element with the characteristic
of pressure discharge. The thermostat is located in the engine
upper thermostat housing.
When the coolant temperature is low, the wax-type element
of the thermostat is in a solid state, the thermostat valve
turns off with the effect of the spring, then the cooling system
stays in the small circulation, ie. the coolant cannot enter the
radiator to circulate, but it can run to the heater core through
the by-pass circuit. When the coolant temperature goes up,
the wax-type element begins to melt down to the liquid state,
its volume also increases, and the thermostat valve gradually
opens with the effect of the push rod, then the cooling system
stays in the large circulation, and when the thermostat is
fully open, all the coolant runs through the radiator. The
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thermostat keeps the coolant at optimum engine operating
temperature.
Radiator and Cooling Fan
The radiator is a straight flow aluminum radiator with a
tank (For the automatic transmission model, the automatic
transmission oil cooler locates in the lower tank of the
radiator. The cooling hose connected to the transmission is
connected to the sleeve of the transmission oil cooler with
nuts). The cooling fan assembly and the air conditioner (A/C)
condenser are fitted on the radiator.
The top of the radiator is secured on the modular front end
panel with the rubber bush, and the lower part is fitted on
the radiator bracket with the rubber bush. The seal sponge
is fitted on both sides of the radiator, to direct the air flow
through the radiator.
The cooling fan assembly is fitted on the back of the radiator.
The cooling fan cools the radiator with the sucked air passing
through the radiator. The vent holes provided on one side
of the fan shroud allow more air flows to pass through the
radiator in use with the cooling fan when driving at a high
speed. The cooling fan low speed resistor is fitted on the left
of the radiator.
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Engine Engine Cooling System

Operation
Coolant Flow

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A = Cold; B = Hot
Based on heat conduction theory, the cooling system transmits can be discharged when the system exceeds the maximum
the heat from the engine pack to the coolant. When the acceptable operating pressure.
engine is in lower temperature, the coolant pump circulates Cooling Fan Control Strategy
the coolant among the engine body, cylinder head and
The cooling fan will operate at a high or low speed, and
passenger compartment heater core. Keep the thermostat
useECM and relay unit to effect control.ECM uses the
closed to prevent the coolant flowing through the radiator,
information from theECT sensor,BCM and air conditioning
and allow a small amount of coolant to pass by to avoid the
pressure switch to control the fan speed, thus restricting the
accumulated pressure too high. When the engine reaches the
engine coolant temperature.
normal operating temperature, the thermostat opens so that
the cold coolant flows from the hose at the bottom of the During the normal operation, the fan will operate in the
radiator into the cylinder block and the hot coolant flows into following temperature conditions:
the radiator. The cold and hot coolant is balanced to maintain Cooling Fan Low Speed High Speed
an optimal engine temperature. When the thermostat is fully Condition
open, all of the coolant flows through the radiator. The extra ON 100 ℃ 112 ℃
coolant generated by heat expansion flows through overflow
OFF 94 ℃ 106 ℃
hose on the top of the radiator and then returns to the
expansion tank. The expansion tank eliminates the gas in the
When the air conditioning system is operating, the fan will
coolant simultaneously. The radiator pressure seal cover with
operate in the following pressure conditions:
pressure limiting valve and vacuum valve separates the cooling
system from the ambient atmosphere. Therefore, the coolant Cooling Fan Condition High Speed
expands and the pressure of the cooling system increases as ON 1.77 Mpa
the temperature rises. The increasing pressure increases the
OFF 1.37 Mpa
coolant boiling point, thus making the engine run at a higher
and more efficient operating temperature without the risk of The fan control strategy includes the engine idling adjustment
coolant boiling. The pressure boost of the cooling system is which can compensate for the additional load generated after
limited, so a pressure discharge valve is fitted on the expansion the fan is turned on. After the ignition key is removed:
tank cover. So the excessive pressure in the cooling system

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Cooling Fan Low Speed High Speed The cooling fan relay may be malfunctioning in the following
Condition conditions:
ON 104 ℃ 110 ℃ • Open in High Speed Relay Coil
OFF 100 ℃ 106 ℃ • Short in High Speed Relay Coil

The cooling fan will operate for 30 seconds to make the
engine obtain additional cooling in hotter environment. When
theECT is malfunctioning, the fan will operate at a low speed.
Cooling Fan Relay Unit
The fan control relay unit is connected to theECM with two
wires, and another wire works as the earth lead of the internal
relay winding. The 12 V power supply is provided to the
cooling fan relay through the No.13 fuse in the engine bay
fuse box. The fan motor is driven by the relay via the output
of the No.13 fusible link in engine bay fuse box. The power
is provided by the relay R6 when the fan operates at a low
speed, and the power is provided by the relay R7 when the fan
• High Speed Relay Contact Point Resistance High
• Open in High Speed Relay Contact Point
• Open in Low Speed Relay Coil
• Short in Low Speed Relay Coil
• Low Speed Relay Contact Point Resistance High
• Open in External Wire
• External Wire Short to the 12 V Power Supply
• External Wire Short to the Ground
• External Wire Resistance High
Warning: Keep away from the cooling fan. The fan may
start automatically without warning, even after the engine

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operates at a high speed. is turned off.

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Engine Engine Cooling System

Service Procedures
Coolant - Drain and Refill
Caution: The engine coolant damages the painted
surface. If the coolant overflows, immediately clean it off
and wash with water.
Drain
1. Remove the bottom wind deflector panel.
Bottom Wind Deflector Panel Removal
2. Remove the pressure seal cover.
Warning: Since injury such as scalding could be caused by
escaping steam or coolant, DO NOT open the expansion
tank cap while the cooling system is still hot. 2. Connect the heater core return hose to the cylinder
3. Set the appropriate container to collect the coolant. block and hold it with clip (2).
4. Detach the clips and disconnect the heater core return
hose from back of the cylinder block.

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3. Prepare the coolant with specified density.
Fluid
5. Detach the clips and disconnect the bottom hose from
4. Loosen the tank pressure cover and fill it until the
the radiator.
coolant reaches the top of the tank and keeps still.
5. Open the expansion tank cover and continue to fill it
until the coolant reaches between MIN and MAX.
6. Make sure that the air conditioner is off.
7. Start the engine and keep it running at 1500 to 2500
rpm. Fill the tank to full as necessary, and screw the
tank pressure cover back on.
8. Continue running the engine at 1500 to 2500 rpm, until
the cooling fan is operating, and then idle the engine
until the cooling fan stops operating.
9. Turn the engine off and cool it for 30 minutes.
10. Check the cooling system for any leakage.

6. Drain the cooling system. Warning: Since injury such as scalding could be caused by
Refill escaping steam or coolant, DO NOT open the expansion
tank cap while the cooling system is still hot.
1. Connect the bottom hose to the radiator and hold it
with clips. 11. Fit the pressure seal cover.
12. Fit the bottom wind deflector panel.

Bottom Wind Deflector Panel Refit

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System Pressure Test Warning: DO NOT exceed the specified pressure value, or
Inspection the cooling system will be damaged.
1. Check the hoses for any cracks or twists and check 6. Visually check the engine and the cooling system for the
the connection of the line. traces of coolant leaking.
2. Loosen the radiator pressure seal cover.

7. Discharge the pressure with the relief valve on

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Warning: Since injury such as scalding could be caused by TEN00021.
escaping steam or coolant, DO NOT open the expansion 8. Remove the hose from the union.
tank cap while the cooling system is still hot. 9. Remove the union from the radiator and fit the
3. Fit theTEN00021 union to the radiator. pressure seal cover.

4. Connect the quick joint of the pressure hose to the

union.

5. Slowly apply the pressure to the system to 93-123 kPa,

and check for leakage.

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Engine Engine Cooling System

Pressure Seal Cover - Pressure Test

(High-Pressure Open: 93-123 KPa Low-Pressure Open: 0-9.8
KPa)
Inspection
1. Visually check the engine and the cooling system for the
traces of coolant leaking.
2. Check the hoses for any cracks or twists and check
the connection of the line.

5. Connect the quick joint of the pressure hose

toTEN00020 union.
6. Slowly apply pressure to the radiator pressure seal
cover to the specified value, and check the pressure
range can maintain 93-123 kPa, the radiator pressure

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seal cover is normal.

3. Loosen the radiator pressure seal cover.

Warning: Since injury such as scalding could be caused by
escaping steam or coolant, DO NOT open the expansion
tank cap while the cooling system is still hot.

7. Discharge the pressure with the relief valve on

TEN00020.
8. Disconnect the quick joint from the pressure hose, and
remove the pressure hose from TEN00020.
9. Remove the radiator pressure seal cover from the
union and fit it to the radiator.

4. Fit theTEN00020 union to the radiator pressure seal

cover.

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Engine Cooling System Engine
Coolant Expansion Tank Cooling Fan
Removal Removal
1. Loosen the fastening clamp between the radiator bleed Warning: Disconnect the battery earth lead before
air hose and the radiator connection end with the removal to avoid the fan motor runs, resulting in personal
clamp plier. injury.
2. Disconnect the bleed air hose and the radiator. 1. Disconnect the battery earth lead.
3. Remove the three screws securing the coolant 2. Remove the coolant expansion tank.
expansion tank.
Coolant Expansion Tank
3. Disconnect the cooling fan electrical connector.

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4. Remove the coolant expansion tank from the vehicle.
Refit
1. Fit the coolant expansion tank on the vehicle.
2. Fit the three screws securing the coolant expansion 4. Remove the cooling fan low speed resistor.
tank to 5.5–7.5 Nm. Cooling Fan Low Speed Resistor
3. Connect the bleed air hose to the radiator. 5. Remove the cooling fan set screws.
4. Secure the radiator bleed air hose with the clamp plier.

6. Remove the cooling fan from the bottom of the vehicle

and fit it.
Refit
Caution: DO NOT remove the fan from the fan motor,
the assembly has passed the dynamic balance test and
adjustment during manufacturing. It cannot reach this
balance requirement when reassembling.
1. Fit the cooling fan on the vehicle.
2. Fit the cooling fan set screws to 5.5–7.5 Nm.

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Engine Engine Cooling System

Cooling Fan Low Speed Resistor

Removal
Warning: Keep away from the cooling fan. The fan may
start automatically without warning, even after the engine
is turned off.
1. Disconnect the battery earth lead.
2. Cut off the two wires of the governor resistor, leaving
the wire on the governor resistor as short as possible.
3. Remove the cooling fan low speed resistor set screws.
4. Remove the cooling fan low speed resistor.

3. Fit the cooling fan low speed resistor.

Cooling Fan Low Speed Resistor
4. Connect the cooling fan electrical connector.

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Refit
1. Fit the cooling fan low speed resistor.
2. Fit the cooling fan low speed resistor set screws to
5.5–7.5 Nm.
3. Connect the two wires between the governor resistor
5. Fit the coolant expansion tank. and the fan.
Coolant Expansion Tank 4. Connect the battery earth lead.
6. Connect the battery earth lead.

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Engine Cooling System Engine
Radiator 8. Remove the radiator upper crossmember.
Removal Radiator Upper Crossmember
1. Disconnect the battery earth lead. 9. Disconnect the cooling fan electrical connector from
2. Drain the coolant. the main wire.
Drain and Refill the Coolant
3. Remove the air cleaner inlet pipe.
Air Cleaner Inlet Pipe
4. Put an appropriate container under the automatic
transmission fluid outlet on the radiator to collect the
flowing automatic transmission fluid. (Only for the
automatic transmission model)
5. Loosen the radiator hose inlet clamp with the clamp
plier, and disconnect the radiator hose inlet from the
radiator.
10. Loosen the overflow hose clamp with the clamp plier,
and disconnect the overflow hose.

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6. Remove the radiator hose outlet clamp with the clamp
plier, and disconnect the radiator hose outlet from the
radiator. 11. Remove the radiator cooling fan assembly fastening
screws.

7. Disconnect the quick joints of the 2 automatic

transmission fluid cooling hoses from the radiator pipe 12. Remove the cooling fan together with the expansion
sleeve. (Only for the automatic transmission model) tank from the top.
Warning: Take extra care, as the drained transmission 13. Lift the radiator up from the base, and move it towards
fluid temperature is very high. the engine.

Caution: Plug the disconnected unions to prevent

contamination entering.

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Engine Engine Cooling System

with the clamp.

12. Add automatic transmission fluid. (Only for the
automatic transmission model)
13. Refill coolant.
Refill Coolant
14. Connect the battery earth lead.

14. Remove the condenser fastening screws.

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15. Remove the radiator from the top.
Refit
1. Place the radiator into the engine bay.
2. Secure the condenser to the radiator with bolts, and
tighten the bolts to 5.5–7.5 Nm.
3. Fit the radiator to the radiator lower crossmember
base.
4. Fit the cooling fan and the expansion tank on the
radiator.
5. Connect the quick joints on the radiator pipe sleeve
that connect the 2 automatic transmission fluid cooling
hoses. (Only for the automatic transmission model)
6. Fit the cooling fan fastening bolts, and tighten them to
5.5–7.5 Nm.
7. Fit the radiator upper crossmember.
Replacement of Radiator Upper Crossmember
8. Connect the cooling fan electrical connector to the
main wire.
9. Fit the radiator overflow hose to the radiator, and
tighten it with the clamp.
10. Fit the radiator hose outlet to the radiator, and tighten
it with the clamp.
11. Fit the radiator hose inlet to the radiator, and tighten it

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Engine Cooling System Engine
Radiator Hose Inlet Radiator Hose Outlet
Removal Removal
1. Drain the coolant. 1. Drain the coolant.
Drain Coolant Drain Coolant
2. Loosen the radiator hose inlet clamp with the clamp 2. Loosen the radiator hose outlet clamp with the clamp
plier, and disconnect the radiator hose inlet from the plier, and disconnect the radiator hose outlet from the
radiator. radiator.

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3. Loosen the radiator hose inlet clamp (1) with the clamp 3. Loosen the radiator hose outlet clamp with the clamp
plier, and disconnect the radiator hose inlet from the plier, and disconnect the radiator hose outlet from the
engine. water pump pipe.

4. Remove the radiator hose inlet from the vehicle. 4. Remove the radiator hose inlet from the vehicle.
Refit Refit
1. Fit the radiator hose inlet to the vehicle. 1. Fit the radiator hose inlet to the vehicle.

2. Fit the radiator hose outlet to the radiator, and tighten 2. Fit the radiator hose outlet to the radiator, and tighten
it with the clamp. it with the clamp.

3. Fit the radiator hose outlet to the engine, and tighten it 3. Fit the radiator hose outlet to the engine, and tighten it
with the clamp. with the clamp.

4. Refill coolant. 4. Refill coolant.

Refill Coolant Refill Coolant

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Tube Joint
Refit
Caution: When assembling the cooling pipe, be sure to
fit it in the given order, and never turn the cooling pipe
after the assembly was finished, otherwise, it may cause
the bolt to break, case to crash or the pipe to leak.
1. Insert the oil pipe into the joint.

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2. Align the oil pipe joint with the transmission case
mounting hole.

3. Temporarily tighten the set nut.

4. Tighten the set nut to the predetermined value.

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Engine Cooling System Engine
Automatic Transmission Case Oil Cooling Pipe 4. Fit the oil cooling pipe fastening bolts, and tighten to
Removal 35-40 Nm.
1. Drain partial transmission oil. 5. Fit the transmission case oil cooling pipe assembly
bracket set bolts, and tighten to 7–10 Nm.
Drain Transmission Oil
6. Fit the transmission case oil cooling pipe assembly to
2. Remove the oil cooling pipe fastening bolts on the oil
the oil cooler.
cooler, and dispose of the gasket seal.
7. Fit the oil cooling pipe fastening bolts, and tighten to
35-40 Nm.
8. Refill the transmission with the transmission oil to the
specified value.
Add Transmission Oil

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Warning: Take extra care, as the drained transmission
fluid temperature is very high.
Caution: Plug the disconnected unions to prevent
contamination entering.
3. Remove the transmission case oil cooling pipe assembly
bracket set bolt (2).
4. Remove the oil cooling pipe fastening bolts (1) on the
transmission, and dispose of the gasket seal.

Caution: Plug the disconnected unions to prevent

contamination entering.
5. Remove the transmission case from the vehicle.
Refit
1. Fit the transmission case oil cooling pipe assembly to
the vehicle.
2. Fit the new gasket seal to the transmission case oil
cooling pipe assembly.
3. Fit the transmission case oil cooling pipe assembly to
the transmission.

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Thermostat 4. Tighten the bolts in order, and the tightened torque is

Removal 8–12 Nm.
1. Drain the engine coolant. 5. Fit the tank water pipe inlet and secure it with clamp.
Warning: Exhaust components may be extremely hot, in 6. Fit the heater water pipe inlet and secure it with clamp.
order to avoid the danger of being burnt, etc., handling
must be performed after the system has sufficiently cooled
down.
2. Loosen the clamp, and remove the heater hose inlet.
3. Loosen the clamp, and remove the tank hose inlet.
4. Unscrew the 5 bolts assembling the thermostat housing
assembly one by one.
5. Remove the damaged thermostat and dispose of it.

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6. Remove the seal washer, and dispose of it.
Refit
1. Fit the new seal washer.
2. Fit the thermostat into the thermostat housing, the
main thermostat sealing wax with the swing valve facing
outwards and the sub-thermostat sealing wax without
the swing valve facing inwards, and rotate both of the
thermostats respectively to locate the swing valve and
the breather hole at the highest point ± 10°as shown in
the illustration.

3. Place the thermostat housing assembly on the

appropriate location of the cylinder head, fit the bolts,
and pretighten them.

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Engine Cooling System Engine
Water Pump
Removal
1. Pre-loosen the 3 bolts connecting the water pump
pulley to the pulley hub, just loosen them, and DO
NOT remove.
2. Remove the accessory drive belt.
Accessory Drive Belt
3. Remove the 3 bolts connecting the water pump pulley
to the pulley hub, and remove the pump pulley.

Refit
1. Since the water pump assembly is a unit, it cannot be
disassembled any more. After the water pump assembly
is removed, inspect the cause of the water pump failure
according to the failure condition. If just the damage of

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the seal ring causes the leakage, then change a new seal
ring. If there is a damage in other parts, it is necessary
to change the water pump assembly.

4. Remove the 3 bolts connecting the water pump housing

to the cylinder block.

2. Fit the water pump (DO NOT lubricate with

Caution: When removing the water pump, be careful not
to pry in radial direction, if it is difficult to pull out, hold
the water pump cover and turn in axial direction until the
water pump is taken out from the cylinder block.
5. Remove the water pump from the engine.
oil lubricant, and apply refrigerant to lubricate is
recommended); rotate the pump in the axial direction
and firmly press it until it snags with the pump mounting
surface of the cylinder block. Notice that location pin is
not designed in the water pump to allow it to rotate in
the circumferential direction, so take care to align the
water pump mounting hole with the appropriate bolt
hole in the cylinder block when fitting.
3. Fit the 3 service bolts connecting the water pump and
the cylinder block, and the torque is 8–12 Nm.
4. Fit the water pump pulley.
5. Fit the 3 service bolts connecting the water pump
pulley and the pulley hub, and just pretighten them.
6. Fit the accessory drive belt.
Refit
7. Tighten the 3 service bolts connecting the water pump

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pulley and the pulley hub, and the torque is 9–11 Nm.
Warning: Exhaust components may be extremely hot, in
order to avoid the danger of being burnt, etc., handling
must be performed after the system has sufficiently cooled
down.

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Engine Cooling System Engine
Special Tools
Tool Description Picture
Number

Cooling System
TEN00021 Test Pressure
Connector

Tank Cover
Opening
TEN00020
Pressure Test

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Tool

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