water pump ISUZU TF SERIES 2004 Manual PDF

6B-2 ENGINE COOLING
General Description
Legend
1 Water Pump
2 Thermostat
3 Radiator
4 Reserve Tank5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater




The Cooling System is a pressurized type, where the water
pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.

ENGINE COOLING 6B-3


Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


Water pump
The water pump is centrifugal type and is driven by timing belt.


Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.





110RS001
Radiator
The radiator is a flow type with corrugated fins.

ENGINE COOLING 6B-7
Water Pump
Water Pump and Associated Parts








Legend
1 Water Pump Assembly 2 O-Ring
3 Bolt

2 3 1

















Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Disconnect radiator hose (on inlet pipe side).
4. Remove timing belt, refer to "Timing Belt" in this manual.
5. Remove water pump assembly.
Inspection
Make necessary repair and 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:

6B-8 ENGINE COOLING











Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with
silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N




m (2.5 kgf




m)
3. Timing belt

Install timing belt, refer to timing belt installation step in
"Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
5. Connect battery ground cable.

6B-12 ENGINE COOLING


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) 88.3 – 103.0
(13.5 – 15.7)
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.
Valve opening vacuum kPa (psi) 1.9 - 4.9
(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 sign 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

Check the rubber hoses for swelling.
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0

ENGINE COOLING 6B-13

Installation
1. Install radiator assembly, taking care not to damage the
radiator core.
2. Install the radiator assembly.
3. Connect reserve tank hose.
4. Connect radiator inlet hose and outlet hose.
5. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolan
t
change) procedure for filling with engine coolant.

Remove radiator cap.

Fill with engine coolant (EC) to the radiator filler neck.

Fill with EC to the "MAX" line on the reservoir tank.

Start the engine with the radiator cap removed and bring to
operating temperature by running engine at 2,500 - 3,000
rpm for 30 minutes.

By EC temperature gauge reading make sure that the
thermostat is open.

If air bubbles come up to the radiator filler neck, replenish
with EC. Repeat until the EC level does not drop any further.
Install the radiator cap and stop the engine.

Replenish EC to the "MAX" line on the reservoir tank and
leave as it is until the engine gets cool.


After the engine gets cool, start the engine and make sure
there is no water running noise heard from the heater core
while the engine runs at 3000 rpm.

Should water running noise be heard, repeat the same
procedure from the beginning.


Main Data and Specifications
General Specifications
Cooling system Engine Coolant forced circulation
Radiator Tube type corrugated (2 tube in row)
Heat radiation capacity 66.3 kcal/h
Heat radiation area 7.08 m2
Radiator front area 028 m2
Radiator dry (weight) 3.1 kg
Radiator cap valve opening pressure 93.3 – 122.7 kpa
Engine coolant capacity 2.0L
Engine coolant pump Centrifugal type
Thermostat Bypass type
Engine coolant total capacity 5.7lit

ENGINE FUEL (C24SE) 6C-9
3. Remove the retainer ring (7) from the fuel tank
with the removal tool 5-8840-2602-0.




140R100035
4. Remove slowly the fuel pump (4) from the fuel
tank as no bend float arm.
NOTE: Cover opening for the fuel pump on fuel tank to
prevent any dust enthering.
5. Discard fuel pump seal (8) because it cannot be
reusable.
Installation
1. Clean the seal surface of the fuel tank and the fuel
pump.
NOTE: If there is dust on the seal surface, it becomes
cause of fuel leak.
2. Install the new fuel pump seal (8) to opening of the
fuel tank as along the groove.
3. Install slowly the fuel pump (4) into the fuel tank as
no bend float arm.
4. Set flange of the fuel pump on fuel pump seal as
mating convexity of the fuel pump and reentrant o
f
the fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank
with the remover tool 5-8840-2602-0.
6. Connector the quick conector (10) into the evapo
tube to fuel pump.
7. Connect the quick connector (6) into the fuel tube
to fuel pump.
NOTE: Pull off the left ckecker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.

8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose
(Pull off the breather hose from fuel tank) and
tighten fuel filler cap until at least one click are
heard.
(2) Apply water soap around the fuel pump seal
area.
(3) Pressure air into the fuel tank from end o
f
breather pipe at 5psi (34.3 kPa/2.8kgf/cm2)
over 15 seconds.
(4) Verify no bubbles around the fuel pump seal
area.
8. Install the fuel tank assembly (9).
NOTE: Refer to “Install the fuel tank” in this section.