water pump ISUZU TF SERIES 2004 Owner's Manual

ENGINE COOLING 6B – 1


SECTION 6B
ENGINE COOLING


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B - 3
General Description .................................................................................................. 6B - 4
Coolant Flow .............................................................................................................. 6B - 4
Water Pump................................................................................................................ 6B - 5
Thermostat ................................................................................................................. 6B - 5
Radiator ...................................................................................................................... 6B - 6
Diagnosis........................................................................................................................ 6B - 7
Draining and Refilling Cooling System ........................................................................ 6B - 8
Water Pump .................................................................................................................... 6B - 10
Removal and Installation .......................................................................................... 6B - 10
Removal...................................................................................................................... 6B - 10
Inspection and Repair ............................................................................................... 6B - 11
Installation.................................................................................................................. 6B - 11
Thermostat ..................................................................................................................... 6B - 13
Removal and Installation .......................................................................................... 6B - 13
Removal...................................................................................................................... 6B - 13
Inspection and Repair ............................................................................................... 6B - 13
Installation.................................................................................................................. 6B - 14
Radiator .......................................................................................................................... 6B - 15
Removal and Installation .......................................................................................... 6B - 15
Radiator and Associated Parts................................................................................. 6B - 15
Removal...................................................................................................................... 6B - 16
Inspection and Repair ............................................................................................... 6B - 17
Installation.................................................................................................................. 6B - 18

ENGINE COOLING 6B – 3

MAIN DATA AND SPECIFICATIONS
Description Item
M/T A/T
Cooling system
Water pump type
Pump to crankshaft speed ratio (To 1)
Delivery volume lit (US/UK gal)/min
Pump speed at 3000 rpm
Water temperature at 30
C (86
F)
Pump bearing type

Thermostat type
Valve initial opening temperature
C (
F)
(Oil cooler thermo valve)
(EGR cooler thermo valve)
Valve full opening temperature
C (
F)
(Oil cooler thermo valve)
(EGR cooler thermo valve)
Valve lift at fully open position mm (in)
(Oil cooler thermo valve)
(EGR cooler thermo valve) Engine coolant forced circulation
Centrifugal impeller type
1.2
100 (26.3/22.2)


Double row shaft

Wax pellet with jiggle valve
82 (180)
76.5 (170)
40 (104)
95 (203)
90 (194)
55 (131)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
Radiator Tube type corrugated
Heat radiation capacity 93.0 kw (79,980 kcal/h)
Heat radiation area
11.63 m
(1.081ft
)
Radiator front area
0.28m
(0.026 ft
)
Radiator dry weight 52 N (5.3 kg/11.7 lb) 53 N (5.4 kg/11.9 lb)
Radiator cap valve opening pressure
93.3
122.7kpa (13.5
17.8psi)
Engine coolant capacity 2.4 lit (5.1 U.S pint) 2.3 lit (4.9 U.S pint)
Engine coolant total capacity 10.1 lit (21.3 U.S pint) 10.0 lit (21.1 U.S pint)

6B – 4 ENGINE COOLING

GENERAL DESCRIPTION
COOLANT FLOW





RTW46ALF001101

The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and thermostat through the bypass hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing
amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now
circulating through the radiator for effective engine cooling.

ENGINE COOLING 6B – 5

WATER PUMP



RTW46ASF000101

A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.

THERMOSTAT














030RY00005
A wax pellet type thermostat is used.
The jiggle valve accelerates engine warm-up.

6B – 10 ENGINE COOLING

WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.




Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.





031R300003
2. Water Outlet Pipe
1) Disconnect the turbocharger-cooling pipe from outlet pipe.
2) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud

5. Fan and Fan Clutch 1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.

030R300001 7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.

030R300002

ENGINE COOLING 6B – 11
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.

Cracks in the water pump body

Coolant leakage from the seal unit

Excessive radial play or abnormal noise in the fan center
when rotate by hand

Excessive thrust play in the fan center (Standard play: less
than 0.2mm)

Cracks or corrosion in the impeller





























Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque N·m(kg·m/lb ft)
20 (2.0/14)

2. Fan Drive Belt and Pulley
1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the
generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt mid-
portion to check the drive belt deflection.
Fan Drive Belt Deflection mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
030R300002


030R300001














3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque N·m(kg·m/lb in)
8(0.8/69)

4. Upper Fan Shroud

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

FUEL SYSTEM 6C – 1


SECTION 6C
FUEL SYSTEM


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 3
General Description....................................................................................................... 6C - 4
Fuel Flow .................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump ........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings ........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21

6C – 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW


RTW46CM F000201


The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.

FUEL SYSTEM 6C – 5


FUEL FILTER AND WATER SEPARATOR
As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the fuel filter. It is used during the air bleeding procedures.

(Except EURO III model)


RTW36CLF000701