2008 GEELY CK radiator

7510. Engine overheat (Table 6)
Table 6Ite m Symptom Trouble shootingRepair or replace
Bad radiator hose Replace
Bad radiator tube strapSupplement welding, otherwise
replace it
Bad cylinder gasket Replace
Cracky cylinder blockRemedy with infiltration technology
or replace it
Poor water pump seal Replace the seal
Replace the anti-freeze liquid
Replace the thermostatBroken we ldSupplement weldingCorrosion result in pin holeFill the pinhole with clear coat,
otherwise replace it
Repair and dredge
Improve the ventilation
Repair or replace the water pump
Troubleshooting, replace the motor if
it is d a ma ge d
Replace
Repair and dredge
Repair or replace the oil pan if there
is o il le a k a ge , r e fill t he o il if it is no t
s up p le me nt e d in t imeCause
Ba d ra diator c over
Clogge d cooling tubePoor ventilationWater
le a ka ge
Anti-fre eze liquid not repla ce d
Bad thermostat
Radiator is
faultyWater
le a ka ge Insufficient
coolantF a ulty fa n vo lta ge
Disabled radiator temperature control
switch
Water jacket is clogged because of too much scale
I ns uffic ie nt e ngine o il ( o il le a k a ge o r d e la ye d filling)P oor
c ooling
Poor FanFaulty water pump

1594Make a simulation test in a way of symptom simulation
5Inspect DTC
6Confirm symptomV. SYMPTOM SIMULATIONNOTES:
The most difficult conditions to handle in the fault troubleshooting are that the fault symptom dose not appear.
Under the circumstances, make sure first to make a comprehensive analysis to the fault described by the
customer, then to simulate an environment that is similar or the same with the conditions when the fault of the
customer's vehicle occurred. No matter how rich the experience of the technician is and how skillful he is, if
he make a fault troubleshooting analysis without confirm the fault symptom, it is inevitable for him to neglect
some important factors and incorrectly guess, which may cause barriers to repair. For example, if a fault
occurs only when the engine is cool or if a fault occurs only caused by a vibration from pavement and so on,
when the engine is checked in the hot or static state, it is no way to confirm. Because of vibration, high-
temperature or seeping water (Vapor) often causes some faults that are difficult to reappear. So, here are
some effective symptom simulation tests.
KEY POINTS OF SYMPTOM SIMULATION TEST:
In the symptom simulation test, no doubt it is important to confirm the fault symptom, but the fault position or
fault components must be also found out. So, before the test and the pre-inspection of connection, narrow the
range of the circuit where faults may occur according to the fault symptom. Then make a symptom simula-
tion test to see if the circuit measured is normal; the fault symptom is also verified at the same time.
1. Way of Vibration: When vibration may be the major cause of the fault.
For example:
(a) Use your hand to gently vibrate the sensor that is considered the cause of the fault, in order to check if it
is ineffective.
(b) Softly rock the connector and harness in horizontal and vertical direction.
Notes: Hard rock may cause the relay circuit open.
2. Way of Spraying Water: When rainy weather or wet environment may be the major cause of the fault.
(a) Spray water on the vehicle to check if the fault occurs.
NOTES:
yBe sure not to directly spray water into the engine compartment. Spray the water on the face of the
radiator to change the temperature and humidity indirectly.
yBe sure not to spray water onto electronic devices and controllers.

299Section 2 Heating SystemHeating system uses mixed temperature adjustment which controls both cold and hot air and is featured in
outstanding temperature adjustment performance. The cold and hot air can be completely mixed at each
outlet and achieve continuous temperature adjustment. The air duct arrangement on the instrument panel is
shown in Figure 2. The air flow channel system is shown in Figure 3.I. Heating System Parameter and StructureHeating system uses water heating structure which uses the engine coolant as the heat source, leads the the
coolant into the heating radiator installed in the vehicle compartment and has the interior or exterior air blow
across the radiator with the blower to increase its temperature. The system consists of the blower assembly,
heating control assembly and heater assembly.Figure 2 Heating Duct ArrangementInside and Outside Air Switch Door Outdoor AirIndoor AirDefoggerIntermidiate outletHeaterBlower MotorEvaporatorAir Mix DoorHeating RadiatorFigure 3 Air Flow Channel System Illustration

3001. Heating System Parameter
Heating system radiating power, blower fan diameter, power dissipation and heater radiator dimension are
show in the table 2.
Table2
Heating System Parameter
2. Blower
Blower is located at the lower part of the goods
compartment. The door inside the blower case is con-
trolled by the servomotor. The exchange of the air in-
side and outside the door can be achieved by adjusting
the door to import the outdoor air and recirculate the
indoor air.
Blower motor uses Permenant magnet DC motor with multple blade fan. In addition, there are a set of
resistance on the blower which adjust the fan, called as adjusting resistor. Blower provides wind supply not
only to the heating radiator, but also to the evaporator in the refrigeration system.
3. A/C Control Mechanism
A/C control mechanism is located in the middle of the instrument panel. All adjustment except the A/C switch
and inside and outside circulation switch are made by rotating the control knob. The A/C control panel is
shown in Figure 4.
1Temperature adjustment control knob: control the mix ratio of the cold and hot air by adjusting the air mix
door, use the control knob to achieve continuous temperature adjustment.
2Outlet control knob: use 4 ranges, different types of air flow adjustment available.
3Inside and outside circulation switch: It can toggles between the introduction of outdoor air and recirculation
of the indoor air. (press the switch for inside circulation)
4Blower switch: when the plum blossom range is closed, the remaining four ranges are used to adjust the
air flow.
5A/C switch: as the switch of the refrigeration system, use press-button with built-in A/C indicator.Dissipation Power/W 4000
Air Flow/(m3/h)280
Power Consumption /W 180
Fan Diameter/mm 140
Overall Radiator Dimension 159.4mm×140mm×49mm Figure 4 A/C Control Panel

301 4. Heater
Figure 5 Heater Door Control Diagram
The heater comprises the heater radiator (heat exchanger), the plastic case forming the air duct, connecting
rods adjusting different air ducts and the door. The two groups of combination doors in the heater case are
connected to the heating control mechanism by the cable. The first group is the two couple action doors
adjusting the air mix ratio that are located in the outlet and inlet each; the second group comprises 4 doors
controlling the air outlet vents, where the upper center one controls the front outlet vent, each of the upper
left and right sides controls a defogger outlet vent and lower foot outlet vent. Figure 5 shows the working
principle of temperature adjustment door. The d) , c) , e) , f) in the figure indicate the outlet air flow direction
as the result of the adjustment of the control knob in the heating control mechanism panel.Hot Wind LocationCold Wind LocationLinkageRadiator CoreRadiator CoreTemperature Adjustment
Door Working PrincipleFoot OutletTo Front OutletTo DefrosterRadiator CoreTo Front OutletRadiator CoreFoot OutletFoot OutletTo Defroster

302Section 3 A/C controlling systemI. Introduction and CompositionIn order to ensure the effective opeation of the A/C system in any operating condition, some advanced
electric control devices are used to protect the A/C system in adverse engine operating condition.
The electrical control part consists of: A/C switch, relay, evaporator temperature sensor, water temperature
sensor, pressure switch, ECU...etc.
A/C system circuit diagram is shown in Figure 6.II. controlling system feature(1) The condenser fan's power is 90W;
(2) The performance of the condenser fan is controlled by ECU, pressure switch;
(3) Cut off the electrical power of the A/C compressor clutch when the water temperature reaches 109°C;
(4) Connect blower switch 9 to rotate the blower motor 6 to ensure A/C normal operation. Connect A/C
switch 10 to output A/C request signal to ECU.
(5) After ECU receives the request signal and the one from the evaporator temperature sensor 17, if the
engine is at idle, ECU first increases the engine speed to 950 ± 50r/min, lest the A/C operation enhance
the load and lower the engine speed or result in engine off. And then the ECU can respond. If the engine
is in accelerating condition, ECU does not respond immediately either, and respond 5 seconds later after
the end of the accelerating condition. ECU send out a A/C control signal from pin 22 to relay 7, command
the relay to suction in. With the low pressure switch 11 closed, the compressor 12 starts to work when the
magnetic clutch suction on. The condenser relay holds in and condenser blower 13 rotates. When high
pressure switch 15 is closed, have the relay 7 hold in and the water tank fan 14 rotates. When the water
temperature sensor 16's temperature is higher than 109°C, ECU shut off the output signal of the pin 22
and A/C stops operation.
(6) When the Refrigeration system pressure is over 1.7MPa, radiator fan will rotato. Disconnect A/C
compressor Refrigeration system power supply when the pressure is over 2.6MPa or less than 0.25MPa;

303Figure 6 A/C System Electrical Appliance DiagramIII. Protecting Device1. Low temperature protection
Evaporator temperature sensor, when the sensed temperature is lower than 3°C, the compressor clutch
is de-energized and stops operation.
2. High temperature protection
Water temperature sensor, when the sensed water temperature reaches 109°C, the compressor clutch is
de-energized and stops operation.
3. Low pressure protection
When pressure sensed by the pressure switch is lower than 0.25MPa, the compressor clutch is de-
energized and stops operation.
4. Voltage protection
When the pressure sensed by the pressure switch reaches 1.7MPa, radiator fan rotates.
5. High pressure protection
When the pressure sensed by the pressure switch reaches 2.6MPa, the compressor clutch is de-energized
and stops operation.
6. Normal pressure
When system pressure reaches 0.25MPa~2.4MPa, control the A/C idle speed. Color of wire:R-Red Bl-Blue Y-Yellow Lg-Light green Br-Brown B-Black P-Pink G-Green W-White Gr-Gray
1. Battery 2. Main Fuse Box 3. Alternator 4. Ignition Switch 5. Idle Rise Valve 6. Blower 7. Relay
8. Blower Regulating Resistance 9. Blower Switch 10. A/C Switch 11. A/C Low Pressure Switch
12. Compressor 13. Condensor Fan 14. Radiator Fan 15. A/C High Pressure Switch
16. Water Temperature Sensor 17. Evaporator Temperature Sensor 18. Electronic Wind Door Actuator Switch
19. Electronic Wind Door Actuator 20. Revolution Sensor 21. Engine ECU

3104. A/C Compressor Removal / Installation1. Disconnect the negative (--) terminal cable from the battery.
2. Drain the refrigerant from the system.
3. Detach the radiator.
4. Loose the drive belt and then remove the drive belt.Notice:•If anything moisture or any foreign matter enters into the Refrigeration system for circulation,
the cooling performance of the Refrigeration system will obviously deteriorate with abnormal
noise. Plug the port immediately after removing any cooling circulation component to prevent
anything moistur or any foreign matter from entering the circulation.5. Remove the compressor inlet and outlet pipe.
6. Removemagnetic clutch connector.
7. Remove the compressor.
8. The installation is in the reverse order of the removal.
9. Adjust the drive belt.
10. Check the Refrigeration system performance.5. The Condenser Removal / Installation1. Disconnect the negative (--) terminal cable from the battery.
2. Drain the refrigerant from the system.Notice:•If anything moisture or any foreign matter enters into the Refrigeration system for circulation,
the cooling performance of the Refrigeration system will obviously deteriorate with abnormal
noise. Plug the port immediately after removing any cooling circulation component to prevent
anything moistur or any foreign matter from entering the circulation.3. Remove the condenser inlet and outlet pipeline to prevent the compressor oil from splashing.
4. Remove condenser fan connector.
5. Remove the engine hood lock.
6. Remove the engine hood lock support brace.
7. Remove the condenser.
8. The installation is in the reverse order of the removal.
9. Check the Refrigeration system performance.The Condenser Installation Description:1. When installing the new condenser, it is recommended to fill certain SW-100 compressor oil into the
refrigerant circuit.Refill: (approximate)
20ml{20 cc }