5 LUBRICATION SYSTEMS

5.1 Function of Lubrication System

Supply the oil to engine part continuouslyis basal task of lubrication system. The
purpose o lubrication
f s i t ystem
r a s o t educing
p s brasion,cool
, c
a bs or bi ng vi br at io n , an ti - ru st in g an d sehe
al in
p ar
g.tT of e ng in e wi ll sbhi
e el de d to
reduce the damage and life of the part will be prolonged.

5.2 Lubrication Mode

Working condition of engine parts are in accordance with their loads and moving
speed.So they need different lubrication intensity and different lubrication method.
1.Pressure lubricating
Oil must be fed in certain pressure to the clearance of the friction surface which
bear heavier loads and move faster, then the oil will form oil-velum and the parts get
lubricated .In a certain pressure, flowing oil can get rid of friction oddments etc and
cool the parts.
The areas need pressure lubrication are: crank main axle journal, axle shell and
connecting rod axle shell，camshaft axle journal and cylinder cover supporter，rocker arm
shaft and rocker arm etc.
2.Splash lubricating
For the moving parts exposed, less load and lower speed, using oil drippings or oil
fog splashed by moving parts to lubricate friction surface.
Parts that use splash oiling are: cylinder wall and piston ring, piston and piston pin,
camshaft and rocker arm of valve mechanism.
3.Apply lubricating grease periodically
For the moving parts of the engine auxiliary system that bear less load and lower
gliding speed，such as water pump bearing ,generator bearing, clutch bearing, tension
adjusting pulley bearing. Because temperature of their friction surface is
lower，applying lubricating grease termly can lubricate them.

5.3 Choice of Oil

There are many kinds oil，selected oil should be accordance with working state of
engine and season.
Glutinosity of oil is an important parameter，its unit is Lis， sorted according to
movement glutinosity at 100℃.
Glutinosity of oil vary with air temperature. Glutinosity of oil reduce with
temperature rising. So choose high glutinosity oil in summer and lower glutinosity in
winter.Engine oil trademark as follows：

5.4 Lubrication Principles

1. Lubrication system structure
1）Lubrication system structure
①source of circulating pressure——oil pump（contain pressure adjusting valve）；
②oil line——main oil line 、lubrication oil line、throttle valve；
③storage set——oil basin；
④filtrate set——oil catcher 、oil filter；
⑤inspect set——oil dipstick、oil pressure sensor；
⑥drain oil jaws、drain oil plug.
1. Lubrication system working flow
 Lubrication system working flow see fig 5-1:
活塞和缸体：Piston and cylinder block 连杆小端：Connecting rod small end
连杆大端：Connecting rod big end曲轴轴颈：Crankshaft journal
缸体油孔：Cylinder body oil hole 机油滤：Oil filter 机油泵：Oil pump 油滤网：Oil filter net
安全阀：Safe valve 旁通阀：By-pass valve 缸体壁：Cylinder wall
1.2.3 摇臂轴轴颈孔：1、2、3 rocker arm shaft journal hole
凸轮轴轴颈：Camshaft journal 第 5 摇臂轴轴颈孔：No.5 rocker arm shaft journal hole
缸盖调整螺钉支座孔：Cylinder cover adjusting screw seat hole
缸盖主油道：Cylinder cover main oil line 缸盖节流嘴：Cylinder cover throttle jaws
油底壳：Oil basin

Fig.5-1 lubrication system main flow sketch map

1)Add oil from oil filler hole of the rocker chamber cover，oil is store in basin through
oil
line in the cylinder cover, cylinder block.
2)Inner meshing type oil pump installed on the crankshaft end run with crankshaft
together，the bigger impurity in oil are filtered by oil catcher strainer，then oil enter
pump through bend pipe of catcher.
3)After oil is supercharged by pump , oil enter filter through outlet of pump and
cylinder block bottom.There is an oil pressure safety valve in oil pump，it begin working
when oil pressure reach about 4.5kg/cm2，oil released reflow to oil basin.
4）Oil enter main oil line in the cylinder through center oil pipe on the oil filter
installing seat after oil is filtrated by oil filter.
5）Main oil line of cylinder body is in the center of cylinder block and parallel to
crank shaft ，it is divided into 5 branch oil lines，impenetrate to 5 main bearing
seats，lubricate crankshaft main bearing .
6）Between crankshaft bearing 1、2、4、5 and connecting rod axle neck 1、2、3、4, should drill
4 inclined oil holes. In order to lubricate 4 connecting rod axle journal with oil
induced from main axle journal.
7）Drill a horizontal oil line between crankshaft No.3 main bearing and main oil line
inclined hole，make it to connect with vertical oil line ，then enter throttle jaws on
cylinder cover bottom.
8)Oil from throttle jaws enter main oil line of cylinder cover，oil in main oil line
lubricate camshaft axle neck and bracket hole on the cylinder cover adjusting screw、No.5
rocker arm hole ，then back into oil basin through cylinder body wall.
5.5 Main Parts of Lubrication System Disassembly ，Inspection and
Installation
●Oil basin and oil catcher(see Fig.5-2)
1-Oil basin;2-Oil catcher; 3-Sealing rubber ring;
4-Washer; 5-Drain oil plug
Fig.5-2 Fig.5-3
Disassembly
1） As shown in fig.5-3，remove under clapboard of gear.
2） As shown in fig.5-4，remove oil basin and oil catcher .

Fig.5-4
1-Synchronous belt shell; 2-cylinder;
3- Oil catcher; 4-oil basin

Fig.5-5

Fig.5-6
Clean
1） Clean assembly surface of oil basin and cylinder body.
As shown in fig.5-5.
2）As shown in fig.5-6，wash filtrate net of oil catcher.
Assembly
According to fig.5-7，gelatinize seal glue to seal surface of oil basin equality.
“A”seal glue ：LETAI 5699
 Fig.5-7

1-Oil catcher
2-Seal rubber ring

Fig.5-8
Fig.5-9
2）Install oil catcher and oil basin.
According to fig.5-8 ，install seal ring to catcher.
Install catcher to synchronous belt shell, tighten it to specified torque..
Tightening torque（a）：11N·m
Assemble oil basin to cylinder body ，then tighten it from middle to two side (arrow as
shown in position), every time tightens one nut.
Tighten them to specified torque.
Tightening torque（b）：11N·m
3）As shown in fig.5-9，assemble washer and drain oil plug to oil basin.
Tighten drain oil plug to specified torque.
Tightening torque（a）：25N·m
4）As shown in fig.5-10，install under clapboard.

Fig.5-10
●Oil pump
Disassembly
1）Disconnect battery cathode. Fig.5-10
2） According to program of reading in front，disconnect synchronous belt shell
As shown in fig.5-11.

1. Oil pump rear cover

 Fig.5-11 Fig.5-12

1-Oil pump rear cover 2-outside rotor

3-inside rotor 4-synchronous belt shell
5-go to set 6-crank front seal
7-pressure adjusting valve 8-spring 9-spring seat 10-clip ring

1- Outside rotor 2- Inside rotor

Fig.5-13 Fig.5-14
Disassembly
1. .机油泵后盖 6. 罩壳油封总成
2. 机油泵针轮 1）As
7. 调压活门shown in fig.5-12，remove oil pump rear cover.
3 机油泵摆线齿轮 8. 弹簧
4. 同步链罩壳 9. 弹簧座
5. 定位套 10. 卡圈
2）As shown in fig.5-13，remove needle wheel and cycloid gear of oil pump.
Inspection
1） As shown in fig.5-14，adjust lib of pump cover seal assy. Replace it if necessary.

1-Crank front seal

2-Oil pump shell

Fig.5- 15

Notice
As fig.5-15，when installing seal of cover shell ，align seal outside end
with belt cover outside end.
Special tool：
（a）：Bearing installer
2） A s s h o w n fi in g5.- 1 ，
3 check needle wheel, cycloid gear, oil pump rear c
synchronous belt cover for abrasion.
Measure
·radial clearance
As shown in fig.5-16，check the radial clearance between needle wheel and synchronous
belt pulley cover.
If t hec learance
i o o l rs utn fp imit,
o o p oeplace
rs ynchronousb eedle e
cover.
Limit clearance of needle wheel and synchronous belt cover is 0.310mm.

Fig.5-16 Fig.5-17

1-Inside rotor
2-Outside rotor

·Side clearance
As fig.5-17，measure side clearance of oil pump with ruler and gauge.
Side clearance limit：0.15mm
Assembly
1）Clean and air parts of disassemble.
2) Apply oil to the n eedle
p o o ulley
p c f p il c ump, s s ycloid
lib,inside ulley,
surface of synchronous belt cover and rear cover of oil pump.
3） As fig.5-13，install needle pulley of oil pump and cycloid pulleysynchronous
to belt
cover.
4） Install oil pump rear cover，tighten 7 screws.Then check if gear work smoothly.
5.6 Maintenance on Vehicle
●Oil checking
1）Check capacity of oil by oil gauge.
2 ） C h e c k t h e o i l f o r c l e a n l i n e s s a n d g l u t i，
n oisfi tiyt i si n t e r f u s ewdi t h c o o l a n t o r
gasoline.
●Change oil
Check engine oil leakage before drain out oil.If leakage exit，insure damaged parts
have been repaired before beginning next step.

1- Oil basin 2- Drain oil plug 1-sign of under limit 2-Sign of upper limit

Fig.5-18 Fig.5-19
1）As fig.5-18，loosen draining screw of oil basin to drain oil.
2）Then clean draining screw.re-install draining screw,tighten it to specified torque.
Tightening torque：（a）：25 n·m
3)Add oil to the upper limit of dipstick（about 3.2L）.Oil filler hole is in
the valve chamber cover, dipstick shown in fig.5-19.
Table 5-1
Engine oil capacity
Oil basin About 3.2L
Oil filter About 0.2L
Other About 0.1L
Totalize About 3.5L

Fig.5-20

1-oil filter
4)Start engine and run it for 3 minutes.Check oil capacity after
minutes.If necessary, add oil to upper limit.
Notice
Engine oil capacity according to table 5-1.

Due to conditions (temperature

、glutinosity etc) have changed， actual oil capacity may be
different with table 5-1.
5）Check oil filter and drain oil screw for leakage.
●Replacing oil filter
1）As fig.5-20，detach oil filter with oil filter spanner（special tool）.
Special tool（A）：Oil filter spanner
2）Apply oil to the new “○” type ring of oil filter.
3 ) A sf i g . 5 - ，
2 1t i g h t e n t h e n e w o i l f i l t e“r ○t”
i ltly p e r i ncgo n t a c t h e m o u n t i n g
surface by hands.

Fig.5-21 Fig.5-22
Notice
Tighten oil filterproperly，till “○”type ring contactmounting surface
for the first time.
4）As fig.5-22，tighten oil filter to 3/4 circle frommounting surface contact point with
oil filter spanner.
Special tool（A）：Oil filter spanner
Tightening torque：（a）：14 n·m
●Oil pressure checking
Notice
Check as follows each item before check oil pressure：
 Oil c apacity
i t o b n .if he
o ill ili evel
l asin
，add so til
ower
u ol pper imit
of dipstick.
 Oil quality：if oil has lost original colour，replace oil.
 Oil leakage ：if finding oil leakage，repair it.
1）As fig.5-23，remove front bumper and oil pressure sensor on the synchronous belt cover.

Fig.5-23
1-Water pump pulley 2-Oil pressure sensor

2) I nstalls t pecial
( p gool o toilo p ressures o riginalp
auge) osition，n he
as fig.5-24.
Special tool：
（A）：Oil pressure gauge
（B）：Oil pressure gauge accessory
3）Start engine, warm up to normal working temperature.
Notice
A f t e r e n g i n e w a r m u p , p u t t r a n s m i s s i oeu
n torna l pno s i t i o n, t h e
vehicle is braked.
4）After engine warm up，measure oil pressure when engine rotation speed is 4000rpm.
4000rpm oil pressure range：330～430kPa
5）Stop engine and detach oil pressure gauge.
6）As shown in fig.5-25，apply glue to thread before installing oil pressure sensor.
Tightening torque（a）：12N·m
7）Start engine，check oil pressure sensor for leakage. If leakage exit, repair it.
8)Install front bumper.

Fig.5-24 Fig.5-25
1-Seal adhesive tape
1-Water pump 2-Water pulley
2-A/C compressor
3-Oil pressure sensor
 6 FUEL SYSTEMS
6.1 General Description
The m ain
c omponents
o t f s a f f het 、fuel
uel p 、fuel
ystem
ump f ilter
a reline. uelnd a
It includes fuel feed line、fuel return line and fuel vapor line.
1.Fuel Pump (Fig.1)

1-Fuel pump 2-Fuel level gauge float 1-In 2-Out

Fig.6-1 Fig.6-2
The fuel pump feed fuel from the fuel tank to the engine; supply enough fuel pressure
and fuel.
The fuel pump is driven by direct current dynamo; It is fixed in the
immerged by the fuel, cooled and lubricated by the fuel. The battery supply power to the
p um p- by -p um p re la y, t he r el ay c an s wi tc h on t he p um p ci rc ui t on ly w he n st ar ti ng a nd t
engine running. So when the engine stops, the pump stops automatically.
There is fuel levelsensor on the pump; it can measure the level of the fuel in the
fuel tank. The pump is installed in the fuel tank, this mode makes the fuel feed system
simple, it is difficult to occur the gas resistance and the fuel leakage .The
installed adoptingflexible installation mode, it can reduce the vibration to transfer to
the pump.

Notice
The fuel pump can work only when there is enough fuel in the fuel tank. If
there isn’t fuel in the fuel tank, pump will burn due to bad cooling. So,
when the engine running or the car is driven, there must be enough fuel in
the fuel tank. The filled fuel is not less than 8L when the car is filled
first or the fuel in the fuel tank is fully consumed in order to keep the
level of the fuel in the fuel tank over the level of the inlet of the
reserve cup. Then the inlet of the pump in the reserve cup is immerged by
the fuel, the car can start successfully.
 2. Fuel Filter
The fuel filter is fixed on the inner side of left member.
The fuel inpours the fuel filter from inlet, pass through the filter element, and
then enter the main pipe through the outlet. shape
The offilter is cylinder
. It isn’ t
disassembled. The diameter of the filter inlet is same as the outlet; the
material of the
filter shell is metal, welded to whole body at the middle flange
6.2 Removal and installation

1.Outline
The step is as follows before checking the fuel system:
(1) Disconnect “-” terminal from battery.
(2) Prohibit smoking, place “Prohibit smoking” sign in working room;
(3) CO2 fire extinguisher must be prepared.
(4) Wear safety glasses;
(5) Remove the fuel tank cap to de-pressurize the fuel tank, and then install the cap.
If don’t release the pressure, the fuel will effuse from the hose du
pressure when removing the hose.
2.Operation
1) Fuel pump
●Removal:
1) Disconnect “-” terminal from battery;
2) Remove the fuel tank cap to de-pressurize the fuel tank, and then install
the cap.
3) Hang up the car.
4) D isconnect t c or bheetweentonnect b whe h ody a iring
t f w arness
harness.
5) Remove the bleeder to drain the fuel.
6) Remove the whole hoses on the fuel tank, incept the rudimental fuel to use
vessel.
Notice
R e c h e c ka n d b e s u r ea l l h o s e s a n d w i r i n g h a r an re es sr e m o v e d b e f o r e r e m o v i n g t h e f u e l
tank.

7) Remove the fuel tank;

8) Remove the main hose; return hose and vapor hose on the fuel pump;
9) Remove the nuts, take down the retainer, then take out the fuel pump from
the fuel tank.
●Inspection:
1) Check the fuel pump:
After taken out the fuel pump, soak it into gasoline (must b
environment), g i t t pet a ts o o rhe f ower
6 t 1 ndN witch
t i n ange
on the flange, mark “1” is to pump positive pole, mark “4” is to pump negative pole.
Visual c w heck t f hether
c f f he p uel
I t p omesi o t romf c eedo ipe.
otherwise the pump goes wrong.
2) Check the fuel level sensor
After taking out the fuel pump, open multimeter and turn to ohm shift, connect positive
and n egative
p t t ooles p o w hem pposite
w “ “ ins,
o t f hichM arked
the float arm slowly and in an even speed along float movement direction. In normal way,
the output resistance shows on multimeter is continuous and various.
failure.
● Installation
It is the reverse of removal procedures, first put the fuel pump (with sealing rin
into the fuel tank, then install the retainer, tighten the nuts
specified torque.
2) Fuel filter
(1) Removal
①Disconnect “-” terminal from battery;
② Remove the fuel tank cap to de-pressurize the fuel tank, then install the cap;
3 Put a container under the fuel filter, remove inlet hose and outlet hose from the fuel
filter;
④Remove the fuel filter (with filter bracket) from the body.
（2）Installation
①Install the fuel filter(with bracket) on the body;
②Install the inlet hose and outlet hose;
③Connect“-”terminal at battery;
④After installing, start the engine to check each part for leakage.

Notice
Connect the right hoses to the filter inlet or outlet, the vent
Painted “IN” is inlet, the vent painted “OUT” is outlet.

3）Fuel tank
● Removal
Process is same as fuel pump removal.
● Clean
Notice
It is impossible to clean up all fuel vapors during the fuel tank clean,
Prohibit repairing near the hot place and fire source, avoid the
contingency to occur.

(1) Remove the fuel tank, then remove all hoses and fuel pump;
(2) Drain the rudimental fuel in the fuel tank;
(3) Move the fuel tank to the clean place;
(4) Fill warm water or tap water into the fuel tank, agitate 、spill, until it is clean ,
replace if it is corrosive.
(5) Drain the wastewater after washing.
 ● Installation
It is the reverse of removal procedures. Note the following:
(1) Be sure to connect the hoses and the pipes correctly;
(2) Be sure the hoses are tighten;
(3)After installing, start the engine, check each part for leakage.
3.Fuel line
● Maintenance service

Caution
As the feed pressure is high to 0.3MPa,the main hose and return hose must use blast
s h e l t e r r u b b e r h o s e , t h e h o s e m u s t b e t i g h t e n b y c l a m op r, f co hr e ca kn y t h e c o n
l e a k a g e . W h e n c h e c k t h e f u e l l i n e , s t r i c t l y p r o h iibnigt trheem orva i l i n l e t a nodu t l e t
hoses to start the engine before checking the fuel pump, otherwise the fuel breakout can
arose fire.

Observe the fuel line and connect or for leakage、burst、damage, assure all clamps and
hoses be tighten ,tightening torque for fuel hose clamp: 3.5~4N﹒m.
Repair the leaking place; make it right in time that the hoses and the clamps wrong
connected. Replace the cracked hoses.

Notice
The engine and fuel pump must stop working before repairing the leakage.

6.3 Emission Control System

◇ Fuel evaporative emission control system
The theory see Fig. 6-3, the system is used to reduce the fuel vapour (HC) into the
atmosphere. When the car run and the engine stops, the fuel vapour produced in the fuel
tank can be gathered by the charcoal in the canister, it is reserved in the canister.
Wh en t he e ng in e ru n, t he c an is te r el ec tr ic c on tr ol v al ve o pe ns i ts v al ve a cc or di ng
environment condition (such as idle condition), the vaporized
canister with the fresh air inpour the manifold to burn. When the engine st
vaporized gas is reserved in the canister.
 Fig. 6- 3
1- INLETMANIFOLD 2–CANISTER 3-TO CARBURETION -4

FUEL TANK

7 ENGINE COOLING SYSTEM

7.1 Standard Value of
Ma intenance
 Standard value
Table 7-1
Items Standard Value
2
Open pressure of radiator cap kPa (kgf/cm ) 93～123(0.95～1.23)
Open temperature of thermostat (℃) 82±1.5
Full open temperature of thermostat (℃) 95
Thermostat lift (mm) More than 8mm at 95℃

7.2 Coolant
 Coolant
Table 7-2
Item Band Capacity (L)
Coolant Shell Freeze Guard (Including Reservoir tank) 4

7.3 troubleshooting
 Troubleshooting
Table 7-3
Condition Probable Cause Correction
1.Laxity or R u p t uAdjust
r e oorf replace
V
belt
2.Lack of Coolant Check coolant level and add
3.Malfunction of thermostat Replace
4.Malfunction of water pump Replace
5.Clogged radiator fin Clean or Repair
6.Leackage of coolant Repair
7 . M a l f u n c t Check
i o and
n replace
o f if necessary
b l o w e r
Engine overheat
motor
8 . M a l f u n c t i o n Check
o f and
b lreplace
o w e rif necessary
circuit
9. Clogged radiator Check and replace if necessary
10.Malfunction of rReplace
adiator
cap
11.Dragging brake Adjust
12.Slipping clutch Adjust or Replace
 Troubleshooting of blower
Table 7-4
Condition Probable Cause Correction
1. Power wire open-circuit Connection
2.Fuse broken Replace
3.No continuity of blower relay Replace
Out of action 4 . M a l f u n c t i o n o f c o o l a n t t e m p e r aCt hu ree c k o r r e p a i r o r r e p l
sensor necessary
5.Malfunction of blower motor C h e c k o r r e p a i r o r r e p l
necessary
1. C ontinuity
o b r fa lltlowerhe elay
Replace
time
Always working
2. M alfunction
o c t f oolant emperature
Check and replace if necessary
sensor

7.4 ON-CAR SERVICE

1.Ispection of the radiator cap open pressure (Fig7-1)
Standard value:94～123kPa
Limit: 88kPa
If necessary replace the cap which is OEC.

Fig7-1
1-Pressure meter 2-Radiator 3-Radiator cap
 Caution
To avoiding scald:
1) Do not remove reservoir tank cap while coolant is boiling.
2) Do not remove radiator cap while engine and radiator are still hot. Scalding fluid an
steam can be blow out under pressure if cap is taken off too quickly.
3) Do not disassembly the cooling system before engine and radiator are cool.
4) D o n o t d i s a s s e m b l y t h e c o o l i n g s y s t e m b e f o r e d i s c o n n e c t i n
battery.
2.Inspection of coolant
(1) W hile
e i cnginec c s lool, i r heck t toolant
c c evel
l n e
should be between“FULL”and “LOW”marks on reservoir tank.
(2) Check coolant for mixing with oil.
3.Replace of coolant
(1) Open radiator cap while engine and radiator are cool:
Turn r adiator
c t “ app o s STOP”
a (ositionp d ward
lowlyw hile nticloc
turning) u t ntil
p l hei c ressure( s oss l “s onfirmed
a p t without
cap down, turn it again anticlockwise.
Caution
For avoiding scald:
Do n otr remove c w adiator
e a r ap a hile
s h ngine
S f nda s adiator
can be blow out under pressure if cap is taken off too quickly.
(2) R eun i ngine
i u t n u dler ntil
h b he h apper t adiator
o r ose
cap. (This indicate that thermostat is open and coolant has return radiator)
( 3) Whi le e ng in e is c oo l, d is co nn ec t ra di at or p lu g an d th e lo we r ra di at or h os e to d ra
coolant out of radiator and heater and engine.
(4) Remove the reservoir tank and drain coolant.
(5) Loosen the water bump plug and drain coolant out of engine (Fig.7-2).

Drain plug

Fig7-2
(6) Retightenthe bump dra in plug and the radiator plug and connect the lower radiator
hose and fill in the cooling system with water. Then run engine in idle until the upper
radiator hose is hot again.
( 7 ) R e p e a t ( 3 ) t o ( 6 ) p r o c e do ur r e4 s t 3i m e s u n t i l t hien dc ro ao l a n t a l m o s t b e c o m e s
colorless.
( 8 ) D r a i n w a t e r o u t o f t h e c o o l i n g s y s t e m t h e n r e i n s t ia nl lp l tu hg e a bn ud m pt h de r a
radiator plug and connect the lower radiator hose.
(9) S crub
a c inner
nd o fr
lean eservoirw s w ithF i oapw w ater.c w alush t
drain. Restall tank and hose.
(10) Add coolant to radiator and reservoir tank (filling radiator to the base of radiator
filler neck and reservoir tank to “FULL” level mark)
Coolant: Shell Freeze Guard Capacity: 3.5L
(11) Install the radiator cap.
(12) Run engine idling until the radiator upper hose is hot.
(13) Run engine at high speed (without load) for several times then stop engine.
(14) When engine is cool, add coolant to radiator and reservoir tank (filling radiator to
the base of radiator filler neck and reservoir tank to “FULL” level mark)
Caution
For avoiding scald:
Do not remove radiator cap while engine and radiator are still hot.
4.Check the relay of blower (Fig.7-3)
Voltage of
battery
Pin number 1 2 3 4 5
No
○ ○
electrifying
Electrifying ○ ○ ○ ○

7.5 Removal and Installing of Thermostat

 Removal (Fig.7-4)
1) Drain coolant out of cooling system and reinstall the engine and radiator drain plugs.
2) Remove the radiator upper hose which is connected with thermostat.
3) Remove the cap of thermostat.
4) Remove thermostat.

Fig.7-4
1-Cap of thermostat 2-Thermostat 3-Seat of thermostat

 Inspection
1) Confirm that the air bleed valve is clean, otherwise engine would trend to overheat.
2) C heck a c ndt tonfirm n a ohat t here’s
i t s o to ny o ther hings
it will do harm to the sealing performance.
3) Check the “O” sealing for damage and other scathes.
4) Check the thermostat valve operation according to the following procedur
Fig.7-6):
 Fig.7-5
① Immerse thermostat in water, and heat water gradually.
② Check the valve starts to open at specified temperature.
Specified open temperature: 82±1.5℃
Full open temperature: 95±1.5℃
Valve lift: min: 8mm
③ If valve starts to open at a temperature substantially below or abo
t e m p e r a t u r e , r te hp el ra mc oe s t a t b e c a u s e s u c h a u n i t w i l l b r i n g a b o u t o
overheating tendency.

Fig.7-6
 Installation (Fig.7-7)

Fig.7-7
1-thermostat 2-bleed valve 3-thermostat seat

1) Install thermostat “O” sealing on the thermostat. Pay attention not to distort and damage.
Caution
Avoid any grease on the “o” sealing, if it damaged replace thermostat.
2 ) Co nf ir m th e bl ee d va lv
ise i ns ta ll ed a cc or di ng t o th e po si ti on s ho ws a s Fi g. 7- 7 (T he
highest position).
3) Install thermostat cap.
4) Connect radiator upper hose.
5) Refill the coolant.
6) Connect negative terminal of battery.
7) Check leakage of coolant after installation.

7.6 Water Pump Disassembly and Installation

　The c entrifugal
t p i u ype i t c ump s s T sedp i n he
i s ooling
by a totally sealed bearing. The water pump itself cannot be disassembled.
1.Disassembly of the water pump (Fig.7-8)

Fig.7-8
A is the water temperature sensor
1) Disconnect negative terminal from battery.
2) Disconnect the lower hose of radiator and drain the coolant.
3) Disassemble the front bumper.
4) Disassemble the heat cover of main exhaust pipe.
5) Disassemble the compressor from bracket (if AC is equipped) and the compressor belt.
Notice
Don not disassemble AC pipes when disassembling the compressor, because this w
about the leakage of refrigeration fluid.
6) Loosen the screw of adjusting belt and the bolt of generator, then Disassemble the V
belt.
7) Disassemble the connecting line of oil pressure switch.
8) Disassemble water pump assembly.
2. Inspection the water pump (Fig.7-9)
Notice
Don not disassemble the water pump, if it has malfunctions, replace it.
1 ) Tu rn w at er p um p by h an d to c he ck o pe ra ti ng s ta bi li ty . If w at er p um p ca n’ t o pe ra
placidly and makes abnormal noise, replace it.
 2) Check impeller for damaged, replace it if necessary.
Notice
Don not disassembles the water pump for checking impeller.

Fig.7-9 Fig.7-10
3. Installation of pump
1) Install a new “O” sealing between water pump and intake pipe.
2) Install water pump on the cylinder, tighten the boltto specified torque (Fig.7-10).
Torque (a): 22N.m
3) Connect oil pressure switch, nip the wire.
4) Install compressor (if AC is equipped) (Fig.7-11).

Fig.7-11 Fig.7-12
1. AC compressor 1-V type belt 2-adjusting bolt 3-fixed bolt

5) Install heat cover of main exhaust pipe.

6) Install V belt.
7) Install compressor belt (if AC equipped).
8) Refill coolant.
9) Connect negative terminal from battery.
4. Water pump belt (Fig.7-12)
 Disassembly
1) Disconnect negative terminal from battery.
2) Remove air cleaner assembly.
3 ) L o o s e ns c r e w o f a d j u s t i n g b e l t a n d t h e b o l t o f g e n e r a tc o rm .p r Re es ms o vr e b e l t
before pump belt (if A/C is equipped)
4) Remove water pump belt.
 Installation
1 ) I n s t a l lw a t e r p u m p b e l t o n w a t e r ppuulmlpe ya n d c rnk
a s h a f tp u l l e ya n d g e n e r a t o r
pulley. Then assemble compressor belt if the maintenance car equipped with A/C.
2) Adjust belt tensile force
As for tensile force adjustment of compressor, consult to interrelated ma
content.
3) Tighten the adjusting belt screw and generator bolt.
4) Connect negative terminal at battery.
 Inspection and adjustment of water pump belt tensile force (Fig.7-13)
Caution
Di s c o n n e c t n e g a t i v e t e r m i n a l f o r m b a t t e r y b e f o r e t h e i n s p e c t i o n a n d a d j u s t m e n
pump belt tensile force. Consult interrelated caution content in this chapter.
Fig.7-13
1.10kg 2.adjusting bolt 3tensioner bolt
1) C heck t d hee amage
o w p xtent
b ( a fc ater
c d ump a elt such
and tidy), replace it if necessary.
2) Check the water pump belt tensile force. Under normal tensile force, the water pump
belt will go down 9-12mm by thumb pressure (about 10kg).
3) Adjust generator position to adjust water pump belt tensile force.
4) Tighten the adjusting belt screw and generator bolt.
5) Connect negative terminal at battery.
CAUTION
Do not remove any part of cooling system before engine and radiator become cool.
Do not remove any part of cooling system before disconnect terminal from battery.

7.7 Removal and Installation of Radiator Upper, Lower Water Hose

1. The work before removal and after installation
 Drain the coolant and refill the coolant
2. Removal service point:
1) Loosen the clamp of the radiator upper and lower hoses. Make marks
for alignment on
hoses and clamps.
2) Disassemble the radiator upper and lower hoses
3. Installation:
1) Insert the radiator upper and lower hose on the outlet and inlet pipe flange.
2) Aim at marks on hoses and clamps at same level then assemble them.
7.8 Removals and Installation of Radiator
1. The work before removal
 Drain the coolant
 Disassemble the front beam
 Disassemble the radiator upper and lower hose
 Disassemble the air intake hose
2. The work after disassembly
It is the reverse of removal procedures.
3.The procedure of radiator removal
1) Disassemble water drain plug of radiator.
 2) Disassemble radiator cap.
3) Disassemble reservoir tank hose.
4) Disassemble reservoir.
5) Disassemble radiator upper hose.
6) Disassemble radiator lower hose.
7) Disassemble the left and right bracket and upper dampers.
8) Disassemble radiator assembly.
9) Disassemble lower insulator
10) Disassemble blower.
Removal service point:
Disassemble the radiator upper and lower hose.
Make marks for alignment on hoses and clamps before removal.
Installation service point:
Installation of the radiator upper and lower hose.
1) Insert the radiator upper and lower hose on the outlet and inlet pipe flange.
2) Align marks on hoses and clamps then assemble them.