S E C T I O NC O

cooHNG
MODEL SYSTEM
J13, J15 & J16 SERIES
E1{GilES

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 Cooling System

COOLINGSYSTEM
CONTENTS

DESCRPTION co2 l N S P . C t . 0 NA \ D A D . I U S T \ , 4 F. N
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COOLA\_ LFVEL co-3 TPFRI/OSTAT ........ co4
D F A I N I N GA N D F L U S HN G PI IVOVALA\D INSIAL .A I ION . , , . . co4
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C O O L T NSCY S T E I. V ............. co,3 INSD-CT ON co5
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DESCRIPTION
The coolingsystemis ofa conven-
tional pressur€type. A cenirifugal
pump,installedon the cylinderblock,
servesto circulatethe coolant.The
pressuretype radialor filler cap is
installedon the radiatorand operates
the cooiing systemat high€r than
atmospheric pressure,
The higherpressure raise!lhe boil-
ing poini of the coolanttnd incr€ases
the coolingefficiencyof the radiator.
When the thermostatb closed,th€
coolantremainsin ihe cylinderh€ad
andblock for swift warmingup of the
engine.After it reachesnomal op"
eratingtemperature, the cooiant ci-
culatesthroughthe radiator.

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FE. CO 1 CooIinEc$tem

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COOLANTLEVEL
The coolant level should be
checkedand maintainedabove the
baffleplateofthe radiatoruppertdnl(.
Caution:To avoid s€riousperconal
injury, neverremoveradiatorcap
quickly*hen engineis hot. Sudden
releaseofcoolingsyst€mpressureis
n it is necessryto removeradiator
capwhen radiatoris hot, turn the
capslowlycounterclock\rise to the
first stop. After a[ pr€ssurcin the
coolingsystemis r€leased, turn cap
passing the stopandremoYe it.
."A
REMOVAL AND
IiISTALLATION
Removal
l. Drain coolantcompletelyinto a
2. Loosenbelt, andihen renovefan
bladeandpu11ey
fron hub.
inlet hosefrom wxtcr
3. Disconnect
Cooling System
DRAININGAND
FLUSHING
THE COOLING SYSTEM
To drain the cooling systemj re-
move radiator crp, releasedfain cock
at the bottom of radirtor and drain
plug on the sid€ of cylinder block. If
the henter system is instailed, set
heaier temperature control !'dve to
olen position. After the coollnt is
drain€d completely, close drain cock
and plug and refill the sysl€m with
-n€
.Dl
@)
&V
Iig. CO-2 Etploded deu of uater pump
purnp.
.+. Rcnove pump assembly
andgas-
kci from cylindclblock.
waterpump,
Note: Prior to remoYing
cl€an the cooling system with
MSSAN CSC (Cooling System
Cleanet.
c03
WATER PUMP
The waterfu,.npis of a centrifugal
type, wtuchis mounredon the cylin-
der block. The fan and pulley ar€
bolted at the pulleyhub. The punp
shaftis sulpo(ed by a doublerow of
ball bearingspressfit.in the pump
body. A mechanicals€alis sentedln
ihe wat€r pump body betwe€nthe
van€andbearingassembly.
The pun! containsan impellerthai
turnson a steelshaftwhich rotdiesin
Theinl€t of the pump
the bal bearing.
is connectedto the radiator'slower
tl
1 BeadnSarsembly
2 Mechrnicalseal
3 Vlne
4 Lock wne
5 Pulleynub
6 covcr
7 Fan Fuuey
lnstallatlon
1. Be sureto clern the gaskelsur-
faccsin contactwilh pumpand cylin-
der b1ock.Always use new gasket
wheninsl lingpurnpassenbly.
2. Aftcr insiallingpump assembly,
fiI1coolingsystemdnd checktbr leaks
3. Instal fan pulley and fan blade.

and tighten fixing bolts securely.
4. lnstal fan belt and adjust for
DISASSEMBLY AND
ASSE'{ELY
DbaBselnbly
1. Removecoverand gas,kets from
purnpbody.
2. Removehub by usinga puller.ln
this case,be carcfulnot to damage
cast-iron
hub.
3, Carefullyremovecast-ironvane
by usinga puiler.
4. Pull out lock wire with a screw'
driver,and then take off bearingas-
s€mblyfrom pump body by usinga
pres9,
Note: Be sure to align b€aringass€m-
bly with a pressarbor, holding
pump body in a viseso as not to
dunagepumpair€mbly.
90.3to 90.7'in
(3,56lo 3.5?in)
FiC.CO3 Sectionaluieuofudtet pump
INSPECTIONAND
ADJUSTMENI
InBpcctlon
Ifany of the followingconditionsis
found, replacedefectiveparts with
newones.
1. Washa[ partsexceptfor bearing
assemblyand rubber sealingpads in
Cooling System
5, Remove mechanicalseal f;onl
purnpbody.
Assembly
l. Instal bearine assembiyinto
pump body by appllng pressureto
outerrace,afterfitting mechanical
seal
into pump body. Be sureto usenew
sealwhenassembling wat€rpump.
2. Insert lock wire into the groove
of bearingthough th€ slit of punp
body to fix bearingassembly.
3. Install vane on shaft of bearing
assembly by usinga pressso that the
correctclearancc betweenthevanetip
and pump body is obraineda! show.
in FigureCO-3,
4. Instal hub on shalt of bearins
assembly by usinga pressso that the
distancebetweenlhe surfaces of pul-
I€y hub and pump coverbecomes the
specifiedvalue as shown in Figure
CO-3.This is very importantfor the
fanbelt operation.
(0.016to 0.024in)
Note: Bearingass€mbly is of a pe.ma-
nent seal€dand lubricatedtype and
must not be washed in cleaning
2. Inspeci respective component
partsfor cracks,or€xcessiyewear.
3. Inspect bearing assernblyfor
roughness or excessiv€
endplay.Clean
off rust or scaleon the shaft or outer
raceof b€aJing assembly.
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4. Inspectmechanical
sealfor wear
or damage-
Adiu5tmcnt
Fan belt shouidbe kcpt adjusted
prop€rly at ali times. A tight belt
causeswear of alternaiorand water
1
pump bearings.A loose belt brings
about jmproperoperationof coolirg
fan,waterpurnpandof aiternator.
Checkthe frn belt slackbetween
alternatorand fan puley by a forceof
10ks (221b).
of fanbelt:
Slackn€ss
8 to 12nm (0.31to 0.47in)
lf adjustrnentis necessary,Ioosen
boli retainingalternatoradjustjngbar
to altefirato.,Movealiernatorioward
or awayfrom engineuntil ihe conect
tensionis obtained.
THERMOSTAT
A wax lellet type thermostatis
mountedin th€ th€rmoslathousingat
the cylinde!headoul1el.
The functioningof the thermostat
is to control ihe flow of coolant,
fscilitatingfast enginewarmup and
regulatingcoolant lemperaiure,The
ihermostaiis designedto open and
closeat predetermined temperatules
and,if not operalingproperly,should
be removedand testedas described
REMOVALAND
INSTALLAIION
1. Draincoolantpartialy.
2. Disconnecitop hose at water
ouUei.
3. Loosen two securingbolts and
then removewater outlei, gasketand
themoslat from thermostathousing.
4. After checkingtherno'stat,re,
instal with a new housinggasketin
p1ace.
5. Reinstallthermostat,gaskeiand
wateroutletand tbentightensecuring
bolts.
6. Replenishcoolantand checkfor
leaks.

INSPECIION
A stigked thefnostat wil prevert
tlrc cooling system from functioning
properly. If tl1e tlEmostat stick in
th€ open position,the enginewarms
up very slowly. [f the thermostat
sticks in the closed position,over-
heating will rerult. Therefore,the
tlEmostat should be inspectedfor
1. Submerge thermostat in hot
Vatveopeningtemperature
above8 mm at 95oC
Maximumvalvelift
Note: It is nec$saryto checka new
theftostat before imtalling it in
the engine.
RADIATOR
Theradiatoris a conventional down
flow typ€ havingthe top andbottom
tar*s to disiributethe coolantflow
uniforrnlythroughthe verticallube of
radiaiorcore.
Theradiatorfiller capis designedto
maintain a pre"set pressure [0.9
kg/cm, (13 psi)l aboveatmospheric
pressure,The reliefvalveconsisting of
a blow-off and vacuumvaive,helps
preventcoolsnt from boiling by giving
pressureto it, On the contrary,when
the pressure is reducedbelowatrnos-
pheric presswe,vscuumvalvealows
air to re-enterinto the radiatorpre-
ventingthe formationof Yacuumin
the coolingsystem.
Cooling Systdm
water soc (9oF) abovetfie tempera-
ture specified
in the folowingtable.
2. Put a mark on a screwdriverat
about8 n'Jn(0.3150in) from the tip,
and checkthe lift of valv€by inserting
thisscrewdver.
3. Now, placeihermostatin water
5oC (9oF) below the specifiedtem-
perature.Under the abovecondition,
valvesshouldbe closedcompletely. FE. CO-4l4spectingthetu@tdt
If ihemostat doesnot operateat
the above specifiedtemperature,it
mustbe replaced
because it cannot be
repaireal.
Standard For tropicalareas
82'C(180.F) 88'C (190'F) (l?0oF)
76.5oC
above8 mm at l00oc above8 mm at 90oC
(0.31sin at 2030F) (0.315in ai 212oF) (0.315in at l94oF)
NETUOVALAI{D
INSTALLAIION
l. Drain coolani completelyinlo a
cleancontainer.
2. Disconnectradiatortop andbot"
3. Removeradiator retainingboltt
and then removeradiatordownward
(the ModelsT20 andA32l) or upward
(theModel520).
4. Instel radiator in the reverse
sequenceof removal.
Also, inspect radiator for water
INSPECTION leakag€using the cap tester at a
Radjatorcapshouldbe ch€cked for pressureof 1.6kg/cm2(22.8psi).
working prersureat reSulartune-up
intervd. First, checkrubber sealon
cap for tear, cracksor deierioration
after cleaningit. Then,installradiator
capon a tester.Ifcapdoesnoi holdor
will not releaseat the specifiedpr€s-
fie- CO 7
If $e above defect is detected,
repaL or replace radiator.
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 Co0ling System

SPECIFICATIONS
Model T20 620 L32l
Engine Jl6 Jl3& Jl5 Jl3& Jl5

Dmensiofl of core 330x446x49 33Ox446 x 32 300x488x49

(Height x Width x Thickne$) rnn (in) ( 1 3 . 0 x 1 7 . 6 x 1 . 9 )( 1 3 . 0 x 1 7 . 6 x 1 . 3 )( 1 1 . 8 x 1 9 . 2 x 1 . 9 )

ed tin andtu

Capworkingpresure kg/cm, (psi) 0.9(13)

pressure
Testing ks/cm?(pst 1.6(23)
watercaPacity liters 5 . 5( 1X , 1 X ) s.4(t%,t%) 6 . 3( t % , t % )
(u.S.sal.,Imper.sal.) ' 7 . 2( l
6.s (2 %, I N) 6.0(tX,t%) %,1 %)

Fanouterdia. [mm (in)] x No. ofblades 3a0(ll.a) z a 310(t2.2\x 4 340(13.4)

x4

AND CORRECTIONS
TROUBLEDIAGNOSES
Condition Correclive
action

Lossofwater Damagedradiatorseams, Repah.

wearin waterpump,
Excessive Replace.
of heaterhoses.
Lesksat connections Repair.
Leakat wat€ftemperaturegauge, Tighten.
Loosejoint!. Tighi€n.
Defectiverubberhoses. Replace.
D€f€ciiv€cylinderheadgasket. Replace.
dndrefill
Checkengineoil for contamination

cylinderblock.
Cracked Replace.
Pull out and seeengineoil levelgaugeto
checkfor waterin crankcase.
Crackedcylinderhead. Replace.
Loosecyiinderh€adbolts. TiBhten.

Overheating Defeciiv€thermostat. Replace.

Radiaiorfins chokedwiti mud, clEff, elc. Cleanout air passage
thorougllyby utingair
preslurefrom the enginesideofthe radirtor.
Incorrectignitionandvalveliming.
Dirty oil anddudgein engine. Refill.
waterpump.
Inoperative Replace.
Looselan belt. Adjust.
radiator.
Restricted Flushradiator.
Inaccurate gauge.
t€mperature Replace.
knpurityin water. Usesoftcleanlvater.
Cooling Systgm

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