samand - ikco-club

SAMAND (XU7JPL3)

Service Manual

Cooling, Manifold and Exhaust

Система охлаждения двигателя

Система выпуска отработавших газов

Михаил

Машинописный текст

Chapter:

Section:

Product: SAMAND XU7JPL3

Cooling,Manifold and Exhaust

I

SAMAND Service Manual

Foreword:

This Service Manual contains descriptions of the following categories for the Samand:

Cooling , Manifold and Exhaust

This manual should be used as service manual and s workbook for training instructors and technicians. We reserve the right to introduce change without prior notice.

Contents

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Technical data

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Special tools

Coolant filling cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electronic measuring tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crankshaft pulley extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft setting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Flywheel stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cooling system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Adjustment and replacement

General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- Conventional hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Draining filling and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Thermostat remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cooling pump remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Water outlet elbow remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Radiator remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Exhaust system and manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical data

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29


Exhaust pipes remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

- Front pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

- Intermediate pipe and centre silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

- Rear pipe and main silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Exhaust system complete remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Exhaust heat shield remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Exhaust manifold remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cooling System

1

Technical data

Thermostat

Starts to open at - 88°c

Fully open at -100°c

Cooling system

Capacity - 7 litres

Antifreeze

28% mixture protection down to - 15°c

50% mixture protection down to - 30°c

Hoses

Hose connection to the radiator is with a bayonet

type connector which seals connection with an

'O' ring.

W74S002

W74S003

W74S004

Torque settings

W74S001

2

1

1. Thermostat housing bolts 15 Nm. 2. Coolant pump bolts 18Nm.

Special tools

Coolant filling cylinder

(-).0173

Electronic measuring tool

SEEM C. Trionic 87

Crankshaft pulley extractor

(-).174

T.(-).0173

T.SEEM87

T.(-).0174

Camshaft setting rod

(-).0132R

Crankshaft setting rod

(-).0153G

Flywheel stop

9765.54

T.(-).0132R

T.(-).0153G

T.9765.54

6 Special tools


System overview

W74D001

6

9

8

1

7

3

95

1. Radiator (incorporating expansion tank

2. Coolant Pump

3. Water Outlet

4. Thermostat Housing

5. Heater

6. Top Radiator Hose

7. Bottom Radiator Hose

8. Heater Hose (Feed)

9. Heater Hose (Return)

Cooling system description

The cooling system is of pressurised type, comprising a coolant pump driven by the timing belt, an aluminium crossflow

radiator with integral expansion tank, electric cooling fans, a thermostat, heater matrix, and all associated hoses and

switches.

The system functions as follows. Cold coolant in the bottom of the radiator passes through the bottom hose to the

coolant pump, where it is pumped around the cylinder block and head passages. After cooling the cylinder bores,

combustion surfaces and valve seats, the coolant reaches the underside of the thermostat, which is initially closed. The

coolant passes through the heater, and is returned via the cylinder block to the coolant pump.

When the engine is cold, the coolant circulates only through the cylinder block, cylinder head, and heater. When the

coolant reaches a predetermined temperature, the thermostat opens, and the coolant passes through the top hose to

the radiator. As the coolant circulates through the radiator, it is cooled by the inrush of air when the car is in forward

motion. The airflow is supplemented by the action of the electric cooling fans when necessary. Upon reaching the

bottom of the radiator, the coolant has now cooled, and the cycle is repeated.

When the engine is at normal operating temperature, the coolant expands, and some of it is displaced into the

expansion tank, incorporated in the side of the radiator. Coolant collects in the tank, and is returned to the radiator

when the system cools.

The electric cooling fans mounted in front of the radiator are controlled by a thermostatic switch. At a predetermined

coolant temperature, the switch/sensor actuates the fan.


General Precautions

W74R001

Warning: Do not attempt to remove the expansion tank

filler cap, or to disturb any part of the cooling system,

while the engine is hot, as there is a high risk of

scalding. If the expansion tank filler cap must be

removed before the engine and radiator have fully

cooled (even though this is not recommended), the

pressure in the cooling system must first be relieved.

Cover the cap with a thick layer of cloth, to avoid

scalding, and slowly unscrew the filler cap until a

hissing sound is heard. When the hissing has stopped,

indicating that the pressure has reduced, slowly

unscrew the filler cap until it can be removed; if more

hissing sounds are heard, wait until they have stopped

before unscrewing the cap completely. At all times,

keep well away from the filler cap.

Do not allow antifreeze to come into contact with your

skin, or with the painted surfaces of the vehicle. Rinse

off spills immediately, with plenty of water. Never leave

antifreeze lying around in an open container, or in a

puddle on the garage floor. Antifreeze can be fatal if

ingested.

If the engine is hot, the electric cooling fan may start

rotating even if the engine is not running. Be careful to

keep your hands, hair, and any loose clothing well clear

when working in the engine compartment.

W74R002

10 Adjustment and replacement

Cooling system hoses

Important

Refer to the warnings given on page 9 of this book,

before proceeding. Hoses should only be disconnected

once the engine has cooled sufficiently to avoid

scalding.

If inspection of the system reveals a faulty hose, it must

be renewed as follow. First drain the cooling system. If

the coolant is not due for renewal, it may be re-used,

providing it is collected in a clean container.

To disconnect a hose, proceed as follows, according to

the type of hose connection.

Radiator hoses

Removal

The radiator hoses are connected to the radiator using

a plastic bayonet-type connection. To disconnect, twist

the end of the hose (with the connector) anti-clockwise

until the clips on the connector are clear of the retaining

lugs on the radiator stub, then pull the end of the hose

from the radiator. Recover the �O� ring from the end of

the hose connector.

11Adjustment and replacement

W74S004

W74R004

To fit

Fit a new �O� ring to the hose connector, then reconnect

the hose.

Twist the end of the hose fully clockwise to ensure that

the retaining clips are engaged with the lugs on the

radiator stub.

Conventional hose connections

To disconnect a hose, use a screwdriver to slacken or

release the clips, then move them along the hose, clear

of the relevant inlet/outlet. Carefully work the hose free.

The hoses can be removed with relative ease when

new - on an older car, they may have stuck.

If a hose proves to be difficult to remove, try to release

it by rotating its ends before attempting to free it. Gently

prise the end of the hose with a blunt instrument (such

as a flat-bladed screwdriver), but do not apply too much

force, and take care not to damage the pipe stubs or

hoses. Do not use excessive force when attempting to

remove the hose. If all else fails, cut the hose with a

sharp knife, then slit it so that it can be peeled off in two

pieces. Check first, however, that a new hose is readily

available.

When fitting a hose, first slide the clips onto the hose,

then work the hose into position. Use standard worm-

drive clips when refitting the hose. If the hose is stiff,

use a little soapy water as a lubricant, or soften the

hose by soaking it in hot water. Do not use oil or

grease, which may attack the rubber.

Work the hose into position, checking that it is correctly

routed, then slide each clip back along the hose until it

passes over the flared end of the relevant inlet/outlet,

before tightening the clip securely.

Refill the cooling system with reference to page ?

Check thoroughly for leaks as soon as possible after

disturbing any part of the cooling system.

W74R005

1

W74R006

1

W74R007


Draining, filling and bleeding

The Cooling System

see precautions page 9

Special tool

1 Filling cylinder (-) 0173

1 With engine completely cold remove the

expansion tank filler cap. Turn cap anti clockwise

until it reaches the first stop. Wait for any pressure

to release. Turn cap anti-clockwise to second stop

and remove.

2 Drain radiator by turning tap anti-clockwise. Tap is

located at the bottom right of the radiator. Fit tube

to collect coolant into container.


W74R008

3

W74R010

2

W74R011

3

3 To assist draining it may be necessary to open

bleed screws located on thermostat housing.]

4 When the flow of coolant stops reposition

container below the cylinder block at the plug on

the front of the cylinder block.

Remove plugs and allow coolant to drain into

container.

Filling

1 Close radiator and cylinder block drain plugs.

2 Open bleed screw at the top of the radiator.

3 Fit the filling cylinder (-)0173 to the expansion tank.

Note: Keep the filling cylinder full to the maximum.

Close the bleed valves as soon as the coolant flow from

them is continuous without bubbles.

Remove the filling cylinder.

Fit the expansion tank cap tighten to the second notch.

Start the engine (engine speed 1500 rpm).

Maintain this speed for three cooling cycles (fans

starting and stopping).

Allow the engine run at idling speed for a few minutes.

Stop the engine.

Wait for at least 10 minutes.

Remove the filler cap carefully.

Top up the coolant lever.

Fit the expansion tank cap. Tighten to second notch.

W74R012

4

4

W74R013

5

W74R014


Thermostat remove and refit

To remove

1 Disconnect battery negative terminal.

2 Drain cooling system.

3 Release any wiring or hoses to improve access to

housing.

4 Remove two bolts securing thermostat housing.

5 Lift thermostat from the housing, noting which way

it is fitted.

6 Test thermostat for opening and closing within

temperatures shown in technical data. If faulty

renew.

If correct check the rubber sealing ring for

damage or deterioration.

To fit

Refitting is a reversal of the removal procedure.

Bleed cooling system.


W74R0211 3 2

4 5

W74R024

W74R0156

5

Coolant pump remove and refit

To remove

Special Tools

1 Camshaft gear setting rod (-).0132R.

2 Crankshaft setting rod (-).0153G.

3 Flywheel stop. 9765.54.

4 Belt tension measuring equipment seem c. Trionic

type 105.5.

5 Crankshaft pulley extractor (-).0174.

1 Drain the cooling system.

2 Raise vehicle and support securely and remove

front right hand road wheel.

3 Remove wheel arch liner.

Note: Radiator bottom hose is fixed to liner with two

plastic ties.

4 Remove accessory drive belt.

5 Release clips and remove fuel pipes from the

upper timing belt cover.

6 Remove two bolts at the base of the cover and

remove cover.

W74R016

7

W74R025

8

9

8

W74R017

10


7 Rotate the crankshaft pulley until the timing hole

in the camshaft sprocket is aligned with its

corresponding hole in the cylinder head.

Note: that the holes are aligned when the sprocket hole

is in the 8 �O� clock position. Insert setting rod

(-).132R into camshaft and setting rod (-).153G into

crankshaft.

The crankshaft and camshaft are now locked in

position, preventing unnecessary rotation.

8 Remove clutch housing bottom closing plate.

9 Lock flywheel with stop 9765.54 and remove

crankshaft setting rod.

10 Remove centre cover. Remove two upper screws,

move cover up to release from locating screws

which retains lower cover.


W74R018

11

W74R019

12

W74R020

13

11 Remove crankshaft pulley using pulley extractor

(-).0174.

12 Remove lower cover. If auxiliary equipment, such

as air conditioning is fitted, it may be necessary to

remove the auxiliary drivebelt tensioner. This will

assist the removal of the lower cover.

13 Loosen the timing belt tensioner pulley retaining

bolt. Pivot the pulley clockwise using a square

section key and tighten the retaining bolt. Support

engine with a jack.

W74R022

14

15

W74R023

16

W74R056

1


14 Mark timing belt for refitting.

15 Remove belt.

Note: All new belts will have alignment marks.

16 Remove five bolts and withdrew coolant pump

and gasket.

The coolant pump is not a serviceable item, if

faulty replace with new assembly.

To fit

1 Using a new gasket fit coolant pump and tighten

to 30 Nm.


W74R026

W74R027

4

4

W74R028

5

2 Ensure that the camshaft setting tool is in

position.

3 Temporarily refit crankshaft and insert setting tool

to ensure crankshaft is correctly positioned. If

correct remove setting tool and remove crankshaft

pulley.

Note: Check timing belt for wear or damage. Renew if

there is the slightest doubt about its condition or if the

vehicle has covered more than 60,000 Km with the

existing belt, renew as a matter of course.

4 Fit timing belt into position ensuring that any

arrows are positioned in the direction of rotation.

If existing belt is being reused, line up marks.

Ensure the front run is taut and any slack is on

the tensioner pulley side.

5 Loosen the tensioner pulley retaining bolt. Using

the square-section key, pivot the pulley

anti-clockwise to remove all free play from the

timing belt.

W74R029

8

7

6

W74R030

W74R033

10

10


6 Remove camshaft setting rod. The special belt

tension measuring equipment should be fitted to

the �front run� of the timing belt. The tensioner

roller should be adjusted so that the initial belt

tension is 30 ± 2 units.

7 Tighten the pulley retaining bolt to 20 Nm.

8 Refit the crankshaft pulley again, tightening

retaining bolt by hand only.

Rotate the crankshaft through at least two

complete rotations in a clockwise direction

(viewed from the right-hand end of the engine).

Do not at any time rotate the crankshaft anti-

clockwise. Both camshaft and crankshaft timing

holes should be aligned so that the locking pins

can be easily inserted. This indicates that the

valve timing is correct.

9 The final belt tension on the �front run� of the belt

should be between 42 to 46 seem units. Readjust

the tensioner pulley position as required, then re-

tighten the retaining bolt to 20 Nm. Rotate the

crankshaft through a further two rotations

clockwise, and re-check the tension. Repeat this

procedure as necessary until the correct tension

reading is obtained after rotating the crankshaft.

Remove crankshaft pulley.

10 Refit lower cover.


W74R034

11

W74R035

12

W74R03113

11 Coat the bolt with a threadlock compound, refit

crankshaft pulley, tighten 110 Nm.

12 Fit centre cover. Ensure bottom fixing is retained

by pushing down onto lower cover screws.

Tighten two upper bolts to 8 Nm.

13 Refit upper cover. Tighten 8 Nm. Refit pipes to

upper cover. Refit wheel arch liner.

Note: Fit new cable ties (bottom hose to wheel arch liner).

14 Tighten the wheel bolts to 85Nm.

W74R032

3

3

4

4

W74R036

5

5

6


Water outlet elbow

To remove

1 Raise vehicle and support securely.

2 Drain coolant system.

3 Remove two front nuts from the engine undertray.

4 Support tray and remove three rear bolts and

lower and remove undertray.

5 From underneath vehicle remove hose to lower

radiator and hose to heater outlet.

6 Remove two bolts and remove water outlet elbow.

Collect sealing ring.

To fit

1 Refitting is a reversal of the removal procedure.

Ensure that the mating surfaces are clean and

check condition of and renew if necessary the

sealing ring. Tighten outlet elbow bolts to .15 Nm.

Refit hoses and fill and bleed the coolant system.


W74R037

3

3 2

W74R038

4

W74R039

5

5

6

6

Radiator remove and refit

To remove

1 Drain cooling system. See page 12

2 Remove air intake hose.

3 Remove 2 screws and move map sensor

complete with bracket connector and hose.

4 Disconnect the upper radiator hose.

5 Raise vehicle and remove two nuts at the front of

the body undertray.

6 Support the undertray and remove three bolts

from the rear of the undertray. Remove undertray.

W74R040

7

8

W74R041


7 From underneath vehicle remove lower coolant

hose to radiator.

Note: this operation can be difficult.

8 Release two wire clips at each end of the radiator

and push toward engine slightly and lift up and

out of the vehicle.

To fit


Note: ensure the lower lugs are correctly engaged with

the mounting rubbers in the body panel. Check �O� rings

on hose connections to radiator and renew if necessary.

Refill and bleed coolant system.

Exhaust system and manifold

25

Technical data

Torque settings

W74S005

4

5

2

3

1

1 Exhaust manifold to cylinder head 35 Nm

2 Heat shield to exhaust manifold (long bolts) 10 Nm

3 Heat shield to exhaust manifold (short bolts) 10 Nm

4 Exhaust front pipe to exhaust manifold 10 Nm

5 Front pipe/intermediate pipe/rear pipe clamping rings 20 Nm


System overview

W74S002

Exhaust Manifold & Exhaust Pipes

The exhaust system consists of 3 parts.

1 Front pipe.

2 Intermediate pipe and centre silencer.

3 Rear pipe and main silencer.

The front pipe is of the spring loaded ball type to allow

for movement in the exhaust system.

All other joints are secured with clamp rings.

The system is secured throughout it length with rubber

mountings.

An earth strap is fitted from the exhaust pipe to the

body at the front pipe to centre silencer clamp fixing.

A heat shield is fitted underneath the fuel tank.


Exhaust pipes remove and refit

W74R042

W74R043

Each section of the exhaust can be removed

individually or the complete system can be removed as

a unit if one part needs attention it is easier to remove

the whole system and separate section on a bench.

Front pipe


2 Remove nuts securing front pipe to exhaust

manifold. Recover spring cups and springs.

3 Remove nuts, washers and bolts from front pipe

to intermediate pipe clamp rings.

Note: That the earthing strap is fixed to clamp bolt.

W74R044

4

W74R045

1

W74R046

2


4 Remove front pipe and collect exhaust ball head.

Intermediate pipe and centre silencer

1 Remove nuts, washers and bolts from front pipe

to intermediate pipe clamp rings.

Note: That the earthing strap is fixed to clamp bolts.

2 Remove nuts, washers and bolts from the

intermediate pipe to the rear pipe clamping rings.


W74R047

3

W74R048

1

W74R049

3 Release mounting rubber and remove

intermediate pipe.

Rear pipe & main silencer

1 Remove nuts, washers and bolts from the rear

pipe to the intermediate pipe clamp rings.

2 Release rear pipe and main silencer from the two

retaining rubbers and remove rear pipe.

W74R050

2

2

W74R051

3

W74R052


Exhaust system complete remove and refit.

To remove


2 Remove nuts securing front pipe to exhaust


3 Remove earth strap at the body fixing point.

4 Remove two rubber mountings from rear pipe and

main silencer.


W74R053

5

W74R055

2

1

1

1

1

5 Remove rubber mounting at the intermediate pipe

and remove exhaust system complete.

To fit


Exhaust heat shield remove and refit

1 Remove four fixing screws to fuel tank.

2 Remove shield from behind exhaust pipe.

To fit


W74R0573

W74R058

44

44

4

W74R059

7

6

5


Exhaust manifold remove and refit

To remove

Note: To remove the exhaust manifold care must be

taken as it is a difficult operation to undertake because

the upper heat shield is also the manifold gasket.

1 Disconnect battery earth cable.

2. Raise vehicle.

3. Remove exhaust front pipe from exhaust


Remove four lower nuts fixing manifold to cylinder

head

4 Lower vehicle. Remove air intake pipe. Release

two clips and remove two screws, remove air filter

cover.

5 Remove three pipes from cylinder head cover.

6 Release and move two fuel pipes aside.

7 Release pipe.

Note: The pipe is fixed also at ignition coil bracket.


W74R060

9 5 1 4 8

10 6 2 3 7

W74R061

9

9

10

10

10

W74R06111

8 Remove ten bolts in the sequence shown and

remove cylinder head cover/air cleaner assembly.

9 Remove two long bolts and washers from heat

shield/gasket assembly. Collect spacers.

10 Remove two bolts from both ends of the lower

heat shield and withdraw heat shield.

11 Carefully lift upper heat shield gasket and remove

four upper nuts fixing manifold to cylinder head.

To fit

Refitting is a reversal of the removal procedure. Check

condition of heat shield/gasket assembly and renew if

necessary.

Technical Department Subject:

Cooling , Manifold & Exhaust Page: 35 of 41

Ref. No :1303R01802681/1

Cooling,Manifold & Exhaust IKCO Export after sales services department



Ref. No :1303R01802681/1


samand - ikco-club

Documents