4.4. Search and elimination of malfunctions of the cooling system

Check of tightness of the cooling system
In certain cases leakage of a radiator can be found by simple addition of water in a radiator. For acceleration of detection of leak it is recommended to clear radiator surfaces of dirt.
1. Remove dirt and the insects slaughtered into a radiator core lattice, having used an ordinary hose without nozzle. The excessive pressure of water can damage radiator plates.
2. Rub the block of tubes a brush with a soft bristle, using clear hot water or hot water with small additive of the washing reagent.

Check of tightness of the cooling system on the car the Aluminium and plastic radiator can be checked by means of the pump and the manometer. On the cold engine, remove a stopper from a broad tank, connect the manometer and create the normal working pressure which is not exceeding 138 kPa.
You watch behavior of an arrow of the manometer which can demonstrate existence of leaks. Examine a radiator and other details of the cooling system regarding leak of cooling liquid. If necessary repair hoses and their connections. Check also tightness of a stopper of a broad tank.
At detection of leaks in a radiator mark area from where cooling liquid that this place could be found easily after removal of a radiator from the car follows.

Check of tightness of a radiator with removal from the car

At service of a radiator do not use capacity for evaporation or capacity which were used at service of copper or brass radiators. The gumboil, acid or the caustic soda remaining in such capacities can react with aluminum and lead to a radiator exit out of operation. At service of aluminum and plastic radiators it is strongly recommended to have the separate test container with clear water.

Fig. 4.2. An aluminum radiator with branch pipes of the heat exchanger of cooling of transmission liquid: 1 – rubber test stopper; 2 – branch pipes of the heat exchanger of cooling of transmission liquid

1. Insert test connecting details or rubber test covers in entrance and output branch pipes. Isolate branch pipes of the heat exchanger of cooling of transmission liquid for its protection and prevention of an effluence of liquid (fig. 4.2).
2. Connect the device for creation of pressure and gradually increase pressure to achievement of 138 kPa, but do not exceed pressure of 138 kPa. You watch the manometer to find reduction of pressure. For detection of small leaks water the repaired site and you monitor emergence of bubbles (in this case addition in water of weak solution of detergent very much helps). If the big bathtub with water is available, the radiator can be shipped in this bathtub and to carry out test for existence of emergence of bubbles.

The leaks which are subject to repair
On an aluminum and plastic radiator it is possible to eliminate two types of leaks: leaks through sealing laying and leaks in the block of tubes of a core of a radiator. Leaks in plastic tanks are not subject to repair. Leaks in the block of tubes can be in the tube or in connection between a tube and a collector. Leakages of laying can be between plastic tanks and collectors or in connections between branch pipes of the heat exchanger of cooling of transmission liquid and tanks. Some types of leaks can be repaired without removal of a radiator from the car, however it is usually best of all to remove a radiator for carrying out repair.

Elimination of leaks in laying of a tank

Fig. 4.3. Use of flat-nose pliers (1) for a bending of petals

It is easy to take leak through laying of a tank for leakage of the tank or a collector. If the leak happens in laying in a junction to a collector, bend petals by means of flat-nose pliers with a clamp (fig. 4.3). If it does not help to eliminate leak, remove a radiator for further survey.

Fig. 4.4. Installation of the tool (a) and the direction an otzhatiya (b) for bending back of a petal

1. By means of the J33419-1 screw-driver unbend petals, except for the petals located under inlet and final branch pipes and under jellied mouths. For bending back of a petal insert the tool under a petal and with effort pull towards a tank (fig. 4.4). Unbend petals exactly so that it was possible to remove tanks.

Be careful not to unbend petals too strongly since it can lead to breakage of a petal. If on one party of a collector more than three petals or two next petals are broken, the block of tubes needs to be replaced.

2. Raise a tank and take it from under not unclenched petals. For removal of laying knock on a tank with a hand. Flat-nose pliers unclench the remained petals.
3. Remove and throw out laying.
4. Clear a collector and a flute under laying of dirt and the remains of old laying.
5. Clear the condensing edge of a plastic tank.
6. Examine the surface of contact of a collector with laying and the condensing tank edge on existence of traces of leaks. Clear or repair surfaces, having removed dirt, agnails and roughnesses.
7. If the tank is equipped with the heat exchanger of cooling of transmission liquid, remove it and establish on a new tank.
8. Dip new laying into cooling liquid or moisten its surfaces with liquid and establish it on a collector surface. Cooling liquid will help to hold laying on the place.

Fig. 4.5. Installation of a tank on the block of tubes and the place of a bending of 4 petals

9. Install a tank and laying on the collector. Fix them together, having bent four petals, as shown in fig. 4.5.

Fig. 4.6. Sequence of a bending of petals of fastening of a tank of a radiator

10. In the sequence given on fig. 4.6 bend other petals around a collector, using for this purpose flat-nose pliers or the special tool.

Draw in petals in the same sequence which is used for tightening of bolts of fastening of a head of cylinders – from the center to edges.

11. Replace the block of tubes if from one of the parties more than three petals or two next petals are broken.
12. If acted, install the crane of discharge of cooling liquid.
13. Check tightness of a radiator.

Replacement of laying of the heat exchanger of cooling of transmission liquid
For replacement of the heat exchanger of cooling of transmission liquid it is necessary to remove a reception tank, however replacement of laying can be made without removal of a tank.
1. Remove a radiator and put it on a plain surface.
2. Turn off the lower nut of fastening of the heat exchanger of cooling of transmission liquid and weaken the top nut.

Fig. 4.7. Use of a small hook (1) for laying extraction (2) heat exchangers of cooling of transmission liquid

3. Press a cooler branch pipe into an opening and by means of a small hook take laying (fig. 4.7).
4. Air drain all privalochny surfaces on a tank and the heat exchanger of cooling of transmission liquid.
5. Establish new dry laying. Make sure that it correctly was established in inflow of an opening.
6. Through an entrance or exhaust outlet of a tank push a branch pipe of the heat exchanger of cooling of transmission liquid in an opening.
7. Screw a nut, without tightening it it is final.
8. Similarly replace the second laying.
9. Screw a nut and tighten both nuts of the heat exchanger of cooling of transmission liquid with the moment of 20 N • m. Do not exceed effort not to damage laying.
10. Check tightness of a radiator.

Replacement of the heat exchanger of cooling of transmission liquid
1. Remove a reception tank.
2. Turn off nuts of fastening of branch pipes of the heat exchanger.
3. Take the heat exchanger and its laying from a tank.
4. Remove old rubber laying and throw out them. Clear and drain sealing surfaces.
5. Dress new rubber laying on the new heat exchanger and install it in a tank opening. Carry out this operation very accurately not to shift laying and not to establish them with a distortion. Laying at installation has to be dry and pure, without dirt and oil.
6. Screw and accurately tighten nuts on branch pipes.
7. Tighten nuts the moment of 20 N • m as excess of the moment of an inhaling can lead to damage of rubber laying.
8. Install a tank into place.
9. Check tightness of a radiator.