Xe ô tô hyundai excel toàn tập hyundai excel - P8

Tài liệu xe ô tô hyundai excel toàn tập hyundai excel

COOLING SYSTEM Return To Main Table of Contents GENERAL COOLING SYSTEM RADIATOR 11 RADIATOR CAP 13 WATER PUMP 14 THERMOSTAT 16 WATER TEMPERATURE GAUGE UNIT 17 WATER CUT VALVE 18 GENERAL GENERAL SPECIFICATIONS Cooling method Cooling system Quantity Radiator Type Performance Radiator cap Main valve opening pressure Vacuum valve opening pressure Water pump Thermostat Water-cooled, pressurized, Forced circulation with electrical fan 5.0 lit (5.3 U.S.qts., 4.4 Imp.qts.) Pressurized corrugated fin type 26,700 Kcal/h 78-98 kPa (11.3-14.2 psi, 0.8-1.0 kg/cm2) -4.9 kPa (-0.71 psi, -0.05 kg/cm2) or less Impeller of centrifugal type Type Valve opening temperature Full-opening temperature Valve lift, fully open Identification mark Drive belt Wax pellet type with jiggle valve 88°C (190°F) 100°C (212°F) mm (0.31 in) or more 88 (Stamped on flange) Type Water temperature gauge unit V-ribbed belt Type Resistance Thermistor type 90.5-117.7 R at 70°C (158°F) 21.3-26.3 R at 115°C (239°F) Water temperature sensor (for vehicles with automatic transmission Type Switching temperature Automatic transmission oil cooler Quantity Performance Heat-sensitive thermistor type Switches “ON”’ at 50°C (122°F) or more 0.05 lit (0.05 U.S.qt., 0.04 Imp.qt.) 1,160 kcal/h SERVICE STANDARD Standard value Coolant concentration 25-2 30-60% GENERAL TIGHTENING TORQUE Nm kg.cm Ib.ft Alternator support bolt and nut 20-25 200-250 14-18 Alternator brace bolt 12-15 120-150 9-11 Water pump to cylinder block 12-15 120-150 9-11 Water pump to cylinder block (alternator brace mounting) 20-26 200-270 14-20 Water pump pulley Water temperature gauge unit 8-10 80-100 6-7 29-39 300-400 22-29 Water temperature sensor 29-39 300-400 22-29 Engine oil cooler bolt 29-34 300-350 22-25 25-3 GENERAL SPECIAL TOOLS 25-4 GENERAL TROUBLESHOOTING Symptom Probable cause Remedy Leakage of coolant Heater or radiator hose Faulty radiator cap Thermostat housing Radiator Water pump Repair or replace parts Tighten clamps or replace Replace gasket or housing Replace gasket or housing Replace parts Clogged radiator Foreign material in coolant Replace coolant Abnormally high coolant temperature Faulty thermostat Faulty radiator cap Replace parts Restriction to flow in cooling system Clear restriction or replace parts Loose or missing drive belt Adjust or replace Faulty water pump Replace Faulty temperature gauge or wiring Faulty electric fan Faulty thermo-switch in radiator Insufficient coolant Repair or replace Repair or replace Replace Refill coolant Abnormally low coolant temperature Faulty thermostat Replace Faulty temperature gauge or wiring Repair or replace Leakage from oil cooling system Loose connections Retighten Cracked or damaged Hoses Pipes Oil cooler Replace Inoperative electrical cooling fan Damaged Thermosensor Electrical motor Radiator fan relay Wiring Low coolant level Replace or repair 25-5 GENERAL COOLANT LEAK CHECK Wait until radiator is cool (less than 38°C, 100°F) Loosen radiator cap Confirm that the coolant level is up to the filler neck Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm2) pressure Hold for two minutes in that condition, while checking for leakage from the radiator, hose or connections CAUTION: Radiator coolant may be extremely hot Do not open the system while hot, or scalding water could spray out causing personal injury Allow vehicle to cool before servicing this system Be sure to completely clean away any moisture from the places checked When the tester is removed, be careful not to spill any coolant from it Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator If there is leakage, repair or replace the appropriate part RADIATOR CAP PRESSURE TEST Use an adapter to attach the cap to the tester Increase the pressure unit the indicator of the gauge stops moving Main valve opening pressure 78-98 kPa (11.3-14.2 psi, 0.8-1.0 kg/cm2) Check that the pressure level is maintained at or above the limit Replace the radiator cap if the reading does not remain at or above the limit NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication SPECIFIC GRAVITY TEST Measure the specific gravity of the coolant with a hydrometer Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference 25-6 GENERAL Relation Between Coolant Concentration and Specific Gravity The following table is applicable only to the specified HIGH QUALITY ETHYLENE GLYCOL (ANTIFREEZE) COOLANT Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20° (68°F) Recommended Coolant Antifreeze DIA-QUEEN LONG-LIFE COOLANT or HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT Allowable concentration [Standard value] 30-60% CAUTION If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected In addition, if the concentration is above 60% both the anti-freeze and engine cooling properties will decrease, affecting the engine adversely For these reasons, be sure to maintain the concentration level within the specified range Do not use together with another brand DRIVE BELT TENSION CHECK AND ADJUSTMENT Depress the belt midway between water pump pulley and alternator pulley with a force of 100 N (22 lb) Measure the belt deflection while depressing for belt tension If the deflection is not within the specification, adjust as follows: Drive belt deflection 7-9 mm (0.28-0.35 in.) 25-7 GENERAL Loosen nut of alternator support bolt “A” and brace bolt “B” Move alternator in direction of arrow “T” to tension belt to specifications First tighten bolt “B” and then tighten bolt “A” to specified torque Tightening toruqe Alternator brace bolt 12-15 Nm (120-150 kg.cm, 9-11 lb.ft) Alternator support bolt and nut 20-25 Nm (200-250 kg.cm, 14-18 Ib.ft) CAUTION An overtensioned belt could cause not only premature wear of belt but also noise and damage to water pump bearing and alternator bearing A loose belt could also cause not only premature wear of belt but also failure of the alternator to generate enough power and consequently a rundown battery or failure of the water pump to turn causing engine overheat and damage 25-8 COOLING SYSTEM COOLING SYSTEM COMPONENTS 25-9 COOLING SYSTEM DRIVE BELT AND PULLEY Removal Loosen alternator support bolt “A” and nut and alternator brace bolt “B” Push the brace side of alternator to relieve belt tension, and remove the belt Remove the waterpump pulley bolts and remove the water pump pulley Tightening torque Alternator support bolt 20-25 Nm (200-250 kg.cm, 14-18 Ib.ft) Alternator brace bolt 12-15 Nm (120-150 kg.cm, 9-11 Ib.ft) Inspection Check following items and replace if defective Check the surface for damage, peeling or cracks Check the belt surface for oil or grease Check the rubber for worn or hardened areas Check the surface of pulley for cracks or damage Installation Install the water pump pulley to the water pump pulley bracket and tighten the bolts firmly After installing belt, adjust the belt tension See “DRIVE BELT TENSION CHECK AND ADJUSTMENT” 25-10 RADIATOR RADIATOR COMPONENTS [ONLY A/T VEHICLES] Motor assembly A/T : Automatic Transmission REMOVAL Disconnect the fan motor plug Set the warm water flow control lever of heater control to the hot position Loosen the radiator drain plug to drain coolant Disconnect the upper, lower hose and overflow tube For vehicles with automatic transmission, disconnect the oil cooler hoses from the automatic transmission CAUTION Plug the ends of the oil cooler hoses and the automatic transmission port to prevent the transmission fluid from spilling out and foreign material from getting in Remove the radiator mounting bolts Remove the radiator together with the fan motor Remove the fan motor from the radiator INSPECTION Check the radiator for bent, broken or plugged fins Check the radiator for corrosion, damage, rust or scale Check the radiator hoses for cracks, damage or deterioration 25-11 RADIATOR Check the reserve tank for damage Check the radiator cap spring for damage Pressure test cap using a cooling system checker Check the radiator cap seal for cracks or damage INSTALLATION Fill the radiator and reserve tank with clean coolant mixture Run the engine until the coolant has warned up enough so that the thermostat valve opens, and then stop the engine Remove the radiator cap, pour in the coolant until it is up to the filler neck of the radiator, and then fill the reserve tank to the upper level Check to be sure that there is no leakage from the radiator, hoses or connections 25-12 RADIATOR CAP RADIATOR CAP COMPONENTS WHEN THE PRESSURE RISES TO THE SPECIFIED LEVEL [78-98 kPa (0.8-1.0 kg/cm , 11.3-14.2 psi)] WHEN THE PRESSURE IS REDUCED TO THE SPECIFIED LEVEL [-4.9 kpa (-0.05 kg/cm2, -0.71 psi)] INSPECTION Check the radiator cap for damage, cracks and deterioration Attach a radiator cap tester to the radiator cap Pump the tester until pointer stabilize If pointer stays for about 10 sec at a point exceeding the service limit, the radiator cap is good 25-13 WATER PUMP WATER PUMP COMPONENTS REMOVAL Drain coolant and disconnect the radiator outlet hose and water by-pass hose from the water pump Remove the drive belt and water pump pulley Remove the timing belt covers and the timing belt tensioner Remove the water pump mounting bolts and remove the alternator brace Remove the water pump assembly from the cylinder block INSPECTION Check the each part for cracks, damage or wear, and replace the water pump assembly if necessary Check the bearing for damage, abnormal noise and sluggish rotation; and replace the water pump assembly if necessary Check the seal unit for leaks, and replace the water pump assembly if necessary Check for water leakage If water leaks from hole “A”, sela unit is defective Replace water pump assembly 25-14 WATER PUMP INSTALLATION Clean gasket surfaces of water pump body and cylinder block Install the new O-ring onto the groove on the front end of the water pipe, then wet the O-ring with water Do not apply oil or grease Install new water pump gasket and water pump assembly and tighten the bolts to specified torque Tightening torque Water pump to cylinder block Head mark “4” bolt 12-15 Nm (120-150 kg.cm, 9-11 Ib.ft) Head mark “7” bolt 20-26 Nm (200-270 kg.cm, 14-20 Ib.ft) Install the timing belt tensioner and timing belt, and adjust the timing belt tension then install the timing belt covers See “Engine”, for detailed procedure Install the water pump pulley and drive belt, and then adjust the belt tension Refill coolant Run the engine and check for leaks 25-15 THERMOSTAT THERMOSTAT COMPONENTS BELOW 88°C (190°F) REMOVAL Drain coolant down to thermostat level or below Remove the outlet fitting and gasket Remove thermostat Heat thermostat as shown in illustration Check to see if valve operates properly Check to determine temperature at which valve begins to open Valve opening temperature 88°C (190°F) Full opening temperature 100°C (212°F) Valve lift (at full opEN) mm (0.31 in.) or more INSTALLATION Check to ensure that flange of thermostat is correctly seated in socket of thermostat housing If thermostat is installed in wrong direction, bottom of thermostat will touch rib inside intake manifold, making it impossible to seat flange in position Install new gasket and water outlet fitting Refill coolant 25-16 ABOVE 88°C (190°F) WATER TEMPERATURE GAUGE UNIT WATER TEMPERATURE GAUGE UNIT REMOVAL Drain coolant down to gauge unit level or below Disconnect the battery ground cable and disconnect harness from the gauge unit Remove the water temperature gauge unit INSPECTION For Manual Transmission Vehicles Heat sensor by holding it under water -Check to see that resistance within the specified range Resistance 90.5-117.5 S-2 at 70°C (158°F) 21.3-26.3 R at 115°C (239°F) For Automatic Transmission Vehicles Terminal A is for the water temperature gauge Check to see that resistance falls within the specified range Terminal B is for the water temperature sensor of automatic transmission Check if there is continuity between terminal B and the body NOTE indicates that there is continuity between the terminals INSTALLATION Apply sealant to threaded portion and tighten to specified torque Tightening torque 29-39 Nm (300-400 kg.cm, 22-29 Ib.ft) Connect the harness to water temperature gauge unit Connect battery ground cable Refill coolant WATER CUT VALVE WATER CUT VALVE COMPONENTS INSPECTION To check the valve, blow compressed air into the valve in direction of arrow and see if the valve operates property Valve opening pressure 70±40 mm Aq Full flow Over 115 lit/min (at pressure = 500 mm Aq) INSTALLATION This valve has an arrow mark on it to show the direction of water flow When this valve is installed in the hose, make sure that the arrow is directed as shown in the illustration (View “A”) 25-18 ... temperature gauge unit 8-1 0 8 0-1 00 6-7 2 9-3 9 30 0-4 00 2 2-2 9 Water temperature sensor 2 9-3 9 30 0-4 00 2 2-2 9 Engine oil cooler bolt 2 9-3 4 30 0-3 50 2 2-2 5 2 5-3 GENERAL SPECIAL TOOLS 2 5-4 GENERAL TROUBLESHOOTING... nut 2 0-2 5 20 0-2 50 1 4-1 8 Alternator brace bolt 1 2-1 5 12 0-1 50 9-1 1 Water pump to cylinder block 1 2-1 5 12 0-1 50 9-1 1 Water pump to cylinder block (alternator brace mounting) 2 0-2 6 20 0-2 70 1 4-2 0 Water... 1 2-1 5 Nm (12 0-1 50 kg.cm, 9-1 1 lb.ft) Alternator support bolt and nut 2 0-2 5 Nm (20 0-2 50 kg.cm, 1 4-1 8 Ib.ft) CAUTION An overtensioned