Copyright ©

Cooling System 1B-1

Engine
Cooling System
Contents
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work. . . . . . . . . . . . . . 1B-2
A List of Defective Phenomena . . . . . . . . . . . . 1B-7
Main Data and Specifications. . . . . . . . . . . . . . 1B-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-16
Fan Clutch, Cooling Fan . . . . . . . . . . . . . . . . . . 1B-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Cooling System 1B-2 Copyright ©
Cooling System
Precautions on Service Work
WARNING:
Do not remove the radiator cap when the cooling water
is at high temperature. Steam or boiling water will gush
out and you may be burnt. To open the radiator cap,
cover the cap with a thick cloth when the cooling water
is cool, release the pressure by slowly turning the cap,
and then remove the cap.

Explanations on functions and operation

Cooling water system
The engine cooling system consists of the radiator,
water pump, cooling fan and thermostat.
The water pump and thermostat circulates the coolant
to rapidly raise the engine coolant temperature for
smooth operation of the engine. In doing so, the coolant
returns to the cylinder block through the bypass pipe.
The coolant is not circulated through the radiator in the
beginning; however, when it reaches the specified
temperature, the thermostat starts to open, allowing the
coolant flow in the radiator to increase gradually.
When the coolant reaches the specified temperature,
the thermostat fully opens allowing all coolant to flow
through the radiator, thus to cool down the engine
efficiently.
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Cooling System 1B-3

4
10

1
11

WSJJ0146

Name
1. Cylinder Block 7. Turbocharger
2. Water Pump 8. EGR Cooler
3. Cooling Fan 9. Cylinder Head
4. Radiator 10. Oil Cooler
5. Reserve Tank 11. Heater
6. Thermostat
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Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
The water pump is a non-disassembled part.

2
1 3

WSJJ0248

Name
1. Fan Center 3. Impeller
2. Bearing 4. Seal Unit
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Cooling System 1B-5

Thermostat
The thermostat is a wax pellet type. It is a bottom
bypass type, and starts to open at the temperature of 82
°C (180 °F). It is mounted in the thermostat-housing
unit.

3
1

WSJJ0147

Name
1. Valve 3. Jiggle Valve
2. Piston

Coolant • Use only genuine Isuzu engine coolant.

1. About the engine coolant concentration • Use engine coolant with a mix ratio in the range
• Take the concentration corresponding to the of 30 to 60% because over heating is likely to
minimum temperature because the freezing occur if the ratio is greater than 60% and
temperature varies according to the corrosion prevention is inadequate if the ratio is
concentration of the engine coolant. less than 30%.

ANTIFREEZE CONCENTRATION (%)

FREEZING TEMPERATURE (°C)

2. Engine coolant concentration measurement

Cooling System 1B-6 Copyright ©
Methods for measuring specific gravity • Fix the temperature of the cooling water being
• Measure the specific gravity and the temperature measured in the range of 0 to 50 °C (32 to 122 °F).
of the cooling water using an anti-freeze specific • Measure the temperature and specific gravity and
gravity meter and thermometer. determine the concentration from the table given
• Take precautionary measures as the boiled cooling below.
water may gush out at high temperatures if the cap
is removed.

• Use a deep container to suit the height of the

specific gravity meter.

SPECIFIC GRAVITY

Name TEMPERATURE (°C)

1. Anti-Freeze Specific Gravity Meter
2. Radiator
LNW46BMH000101

Coolant scooping method

• Measure the concentration using the coolant
scoop.
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Cooling System 1B-7

A List of Defective Phenomena

• Engine overheats
• Engine overcools

Engine overheats

Condition Possible Cause Correction

Engine overheats Cooling water volume is deficit. Add.
Thermometer unit is defective. Replace.
Thermostat is defective. Replace.
Radiator pump is defective. Replace.
Radiator is clogging. Clean or replace.
Radiator cap is defective. Replace.
Engine oil volume is deficient or Add or change engine oil.
incorrect engine oil is used.
Cylinder head gasket is defective. Replace.
The fan belt is loose. Adjust.
Exhaust system is clogging. Clean or replace.
The fuel injection quantity is in Diagnose the engine control
surplus. system.
Fuel injection timing is incorrect. Diagnose the engine control
system.
Starting pressure of fuel injection is Diagnose the engine control
low. system.

Engine overcools

Condition Possible Cause Correction

Engine overcools Thermostat is defective. Replace.

Main Data and Specifications

Water pump Centrifugal impeller type

Pulley ratio 1.03
Thermostat Wax pellet system
Valve opening temperature °C (°F) With jiggle valve 85 (185)
Temperature when fully open °C (°F) With jiggle valve 100 (212)
Valve lift amount at full open mm (in) 10 (0.39)
Cooling System 1B-8 Copyright ©
Water Pump
Components

4 3 2

WSJJ0255

Name
1. Fan 3. Water Pump Pulley
2. Spacer 4. Water Pump ASM

Removal
1. Drain the coolant.
2. Disconnect the radiator upper hose.
3. Remove the fan shroud and fan guard.

WSJJ0263

4. Remove the fan ASM, spacer and water pump

pulley.
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Cooling System 1B-9

1
3 2

4
1

WSJJ0264 WSJJ0256

Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 7. Remove the gasket.
4. Bolt

5. Loosen the tension adjusting bolt (1) of the Inspection

generator and remove the fan belt. 1. Appearance check
• Check for cracks or damage in the pump body.
• Check for cracks and corrosion in the impeller.
• Check for water leakage from the seal unit.
• If you find abnormalities, replace with the water
pump ASM.
2 2. Bearing nut check
• Check the play in the thrust direction.
Standard: 0.2 mm or less (0.0078 in or less)
1 • Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
• If you find abnormalities, replace with the water
pump ASM.

4 3

WSJJ0035

Name
1. Tension Adjusting Bolt
2. Lock Nut
3. Bolt
4. Nut

6. Remove the water pump ASM.

Cooling System 1B-10 Copyright ©
M

4 3

WSJJ0267 WSJJ0035

Installation Name
1. Install the gasket. 1. Tension Adjusting Bolt
2. Install the water pump ASM. 2. Lock Nut
3. Bolt
• Tighten the bolt and nut to the specified torque.
4. Nut
Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)
3. Temporarily tighten the bolt until the water pump 6. After fan belt adjustment, tighten the temporarily
pulley is properly seated in the water pump ASM. fitted water pump pulley to the specified torque.
4. Mount the fan belt, and tighten the tension Tightening torque: 10 N.m (1.0 kg.m/87 lb in)
adjusting bolt of the generator to adjust the tension. 7. Install the fan ASM and spacer.
• Refer to the “Drive Belt”. Tightening torque:
5. After fan belt adjustments, tighten the generator M8 : 25 N.m (2.5 kg.m/18 lb ft)
using the specified torque. M10: 52 N.m (5.3 kg.m/38 lb ft)
Tightening torque:
Bolt: 51 N.m (5.2 kg.m/38 lb ft)
Lock nut: 25 N.m (2.5 kg.m/18 lb ft)
1
3 2

WSJJ0264

Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
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Cooling System

8. Install the fan shroud and fan guard.

Tightening torque: 51 N.m (5.2 kg.m/38 lb ft)

WSJJ0263

9. Connect the radiator upper hose.

10. Pour coolant.
Cooling System 1B-12 Copyright ©
Torque Specifications

N m(kg m/lb ft)

25 ( 2.5 / 18 )

M8 : 25 ( 2.5 / 18 )
M10 : 52 ( 5.3 / 38 )

10 ( 1.0 / 88 lb in )

25 ( 2.5 / 18 )

25 ( 2.5 / 18 )

51 ( 5.2 / 38 )

WSJJ0269
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Cooling System

Thermostat
Components

WSJJ0023

Name
1. Water Outlet Pipe 2. Thermostat

Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Disconnect the radiator upper hose.
3. Remove the engine harness clip.
4. Disconnect the water outlet pipe.
• Disconnect the turbocharger water feed hose
from the water outlet pipe.
5. Remove the thermostat.
• Be careful not to damage the thermostat. 2 1

WSJJ0179

Name
1. Thermostat
2. Jiggle Valve
Cooling System 1B-14 Copyright ©
Inspection Installation
• Place the thermostat in water and increase the 1. Install the thermostat on the position shown in the
temperature while stirring it sufficiently. illustration.
• Measure the temperature when the valve is just • Install the thermostat with its jiggle valve (2)
opened and when it is fully open. facing the front of the engine.

Thermostat valve-opening temperature °C (°F)

85 (185)

Thermostat full-open temperature °C (°F)

100 (212)

Valve lift amount at full open mm (in)

10 (0.39)

2 1

WSJJ0179
2
Name
1. Thermostat
2. Jiggle Valve

2. Connect the water outlet pipe.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)
3
• Connect the turbocharger water feed hose to
the water outlet pipe.
3. Install the engine harness clip.
4. Connect the radiator upper hose.
WSJJ0148
5. Replenish the cooling water stored during the
Name discharge, and check the volume of the cooling
1. Thermometer water.
2. Stirrer
3. A Piece of Wood
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Cooling System

Drive Belt
Components

6
7

1
3
2

WSJJ0024

Name
1. Crankshaft Pulley 5. Tension Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Generator Adjusting Plate
4. Generator 8. Water Pump Pulley

Inspection Drive belts adjustment

Check for the presence of wear or damage in the Adjustment procedure
drive belt and renew the parts if necessary. Adjust simultaneously the generator drive belt for
Check the tension of the belt and adjust if necessary. adjustment of belt.
Inspection procedure 1. Loosen the adjusting plate lock nuts and the
Apply a pressure of 98 N (22 lb) at the center of the mounting bolts of generator on the underside of the
long span of each belt and check the deflection of the generator.
belt. • Loosen the installing bolt under the generator
while holding the nut on the back using a tool.
Deflection of generator drive belt
2. Rotate the adjusting bolts of generator and adjust
When the belt is new the belt (remove and fit).
5 — 6 mm (0.20 — 0.24 in) 3. After adjustments, tighten the adjusting plate lock
When the belt is reused nuts and the mounting bolts of generator on the
7 — 8 mm (0.28 — 0.32 in) underside of the generator using the specified
torque.
Cooling System 1B-16 Copyright ©
• Loosen the installing bolt under the generator
while holding the nut on the back using a tool.
Tightening torque: 5
Nut: 25 N.m (2.5 kg.m/18 lb ft) 7

Bolt: 51 N.m (5.2 kg.m/38 lb ft) 4

2 1

WSJJ0180

Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Tension Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt

Torque Specifications

N m(kg m/lb ft)

25 ( 2.5 / 18 )

25 ( 2.5 / 18 )

51 ( 5.2 / 38 )

WSJJ0200
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Cooling System

Fan Clutch, Cooling Fan

Inspection 2. Inspection (single unit)

If wear, damage or any fault is found during the 1) Warm up the bimetal area of the fan clutch
inspection, replace or repair as required. using a heat gun until the temperature reading
on the thermistor reaches approx. 85°C. Then
Visually check for damage, silicon grease leakage or check if considerable force (clutch torque) is
other faults. required to rotate the fan clutch. At this time, if
the fan clutch rotates easily, this indicates that
1. Inspection (on-vehicle)
the silicon grease is leaked inside. Replace the
1) Before starting the engine, rotate the fan clutch fan clutch with new one.
when it is cold by hand to check if it rotates
easily.
2) Start the engine and warm it up until the
temperature of the fan clutch reaches approx.
85°C. Then stop the engine, and rotate the fan Heat gun
clutch by hand to check if considerable force
(clutch torque) is required to rotate. However, if
the fan clutch rotates easily, this indicates that
the silicon grease is leaked inside. Replace the
fan clutch with new one.

WSJJ0279

Thermistor

WSJJ0278