radiator ISUZU TF SERIES 2004 Owner's Manual

6B – 14 ENGINE COOLING

Thermometer
 Agitating rod
 Wooden piece
















Installation
1. Thermostat
Install the thermostat to the thermostat housing.
2. Water Outlet Pipe
3) Install the water outlet pipe with new gasket to the thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque N ·m(kg ·m/lb ft)
19(1.9/14)

5) Connect the turbocharger-cooling pipe to outlet pipe.
031R300003


3. Radiator Upper Hose
1) Connect the radiator upper hose to the water outlet pipe.
2) The knob of clamp shall be directed to holizonal side.
3) Replenish the engine coolant.

ENGINE COOLING 6B – 15
RADIATOR
REMOVAL AND INSTALLATION
Radiator and Associated Parts




RTW36BLF000101
Legend
1. Radiator Hose
2. Drain Plug
3. Fan Guide, Lower
4. Fan Guide
5. Bracket


6. Reserve Tank Hose
7. Reserve Tank
8. Radiator Cap
9. Radiator Assembly

6B – 16 ENGINE COOLING

P1010064
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





PTW46BSH000101
5. Remove fan guide(1), clips(2) on both sides and the bottom
lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.





RTW36BMH000101
7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking
care not to damage the radiator core with a fan blade.

ENGINE COOLING 6B – 17
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.


Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 93.3





122.7 (13.5





17.8)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.





110RS006

Valve opening vacuum kPa (psi) 1.96




4.91 (0.28




0.71)


Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.

Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all signs of scale and rust.

Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
 Leakage from the radiator
 Leakage from the coolant pump
 Leakage from the water hoses

6B – 18 ENGINE COOLING




110RS005

 Check the rubber hoses for swelling.

Installation
1. Install radiator assembly (9) with hose, taking care not to
damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and
secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the
engine.





RTW36BMH000101

6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.

ENGINE COOLING 6B – 19




RTW36BSH000101

8. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.

Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.


Engine coolant change
Refer to 6B-8 (Draining and Refilling Cooling System).

ENGINE MECHANICAL (6VE1 3.5L) 6A-11
Symptom Possible Cause Action
Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too
low or wrong engine oil Change or replenish
Resistance in exhaust system
increased Clean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrect Replace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shorted Correct or replace
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82
C (180
F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too
high Correct level of engine oil
EGR valve defective Replace

6A-28 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt

5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5884001330
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-29
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using
wrench then remove drive belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover 13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.
2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.
4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.

ENGINE MECHANICAL (6VE1 3.5L) 6A-33
4. Install crankshaft pulley using 5-8840-0133-0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to
the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
6. Install power steering pump assembly and tighten
to the specified torque.
Torque:
M8 bolt: 25 N




m (2.5 kg




m/18 lb ft)
M10 bolt: 43 N




m (4.4 kg




m/32 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

9. Install radiator upper fan shroud.
10. Install air cleaner assembly.