coolant level ISUZU TROOPER 1995 Workshop Manual

(
(
(
MILEAGE/MONTHS
rn
I ffi
IN THOUSANDS
OF
MILES
(USE
ODOMETER READING)
(x 1000
miles)
~ +~
7.5 15 22.5
30
37.5 45 52.5
60
67.5
75
82.5
90
97.5
105
112.5
120 DESCRIPTION
1
CHECK
BATTERY
FLUID
LEVEL
12
2'-'.:j:
:':
';;;;;
I '' ''
,,,,,,,,,:
[}
2
CHECK
ENGINE
COOLANT
LEVEL
12
':iti:·:
(''''/''?
'';?
,,,,,,,;.;.,.,....
,,,~~
3
CHECK
BRAKE
AND
CLUTCH
FLUID
LEVEL
12
:;:;:;:;:·:·:·.
\::':\' '\"':(\':'''''''''
:'·'·'·:·.,.,,,,
d~~~~~~-------------~
)''
'"''''{''''
'}';;o;o;;
l':':':·:o·.·o·····
4
CHECK
FLUID
LEAKS
12
•.•••..••• ,,......
,,,,,,,,,,,
5
* CHANGE
ENGINE
OIL
12
:.•••:•····
f ) : •
: ; ' {
1:':''''
6
*REPLACE
ENGINE
OIL
FILTER
12
{\::::::::;
[:(o:'.
7
CHECK
COOLING
AND
HEATER
HOSES
12
I : ' :
?
,,,.,,,,,.,:,
.. ;
! • !
•••••••••.
8
CHECK
EXHAUST
SYSTEM
12
I
~
J
:
: ••;·,·····,:·:';';·
•••::::::::::·:;.;
I ;J
., ..... .
9
CHECK
FUEL
LINE
AND
FUEL
TANK/CAP
12
10
CHECK
ENGINE
DRIVE
BELTS
24
. .
I
I
11
CHECKTIRESANDWHEELS
12
li
1:;:~:
}::,
..... ::::, .. ,::,:,:,:,·····
j
12
CHECK
STEERING
OPERATION
12
1
r ., .. ,,.,,.
·
I
13
CHECK
BRAKE
LINES
AND
HOSE
12
~
~
<
.,>
/ ':'??i'
}
J
t
''}{
14
CHECK
DISC
BRAKES
12
10
}}
UL
'I I
•....
15
CHECK
BRAKE
PEDAL
PLAY
12
I"
.. )t
16
CHECK
PARKING
BRAKE
12
li
I
17
LUBE
ACCELERATOR
LINKAGE
6
,,.:
....
I
18
CHECK
SUSPENSION
AND
STEERING
12
••·•••·•··•
19
LUBE
BODY
AND
CHASSIS
6
1''''':'''''''''''
20
LUBE
FRONT
AND
REAR
PROPELLER
SHAFT 6
{:
!: • :•••••l
21
CHECK
PROPELLER
SHAFT FLANGE
TORQUE
12
•
22
*CHECK AUTOMATIC TRANSMISSION
FLUID
12
... ,, ,....
@{I{
,,,,,,,,
ttJ
·~+---------------!
23
CHECK
AUTO
CRUISE
CONTROL
LINKAGE
AND
HOSES
12
~ .
:l
!•••:
24
CHECK
CLUTCH
LINES
AND
HOSE
12
25
LUBE
CLUTCH
PEDAL
SPRING,
BUSHING
AND
CLEVIS
PIN
6
l':":"·:"ii
26
CHECK
CLUTCH
PEDAL
FREE
PLAY
12
1/JJ(
21
cHEcK sTARTER SAFETY swiTCH 12
1/,,,,.,,,,,,,,,
,,,,,,,,,
-~~~--~~~~~~-~~~~~[============J
28
CHECK
ACCELERATOR
LINKAGE
12
m ::::::::]
!•'····
'.!
Under
severe driving conditions,
additional
maintenance
is required.
Refer to
"Severe
driving
conditions".
SHADED AREA
INDICATES
SERVICE
TO
BE PERFORMED.
s: ~ 2 -1 m 2 )> 2 n m )> 2 c r­c m ::u n ~ 0 2 Q ~

OB-4 MAINTENANCE AND LUBRICATION
EXPLANATION OF COMPLETE VEHICLE
MAINTENANCE
SCHEDULE
Brief explanations of the services listed in the
preceeding Maintenance Scheduled are presented
below.
Replace
all questionable parts and note any necessary
repairs
as you perform these maintenance
procedures.
FRONT AND REAR AXLE LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace the front and rear
axle lubricant at 15,000
miles (24,000 km) and 30,000 miles (48,000 km) and
after every 30,000
miles (48,000 km) or operation
thereafter.
MANUAL TRANSMISSION LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace the transmission
lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000
miles (48,000 km) of operation there­
after.
TRANSFER CASE LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace
the transfer case lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000
miles (48,000 km) of operation there­
after.
AIR CLEANER ELEMENT REPLACEMENT
Replace the air cleaner under normal operating
conditions every 30,000 miles (48,000 km).
Operation
of the vehicle in dusty areas will
necessitate more frequent replacement.
SPARK PLUG REPLACEMENT
Replace the plugs at 30,000 mile (48,000 km) intervals
with the type specified at the end of this section.
COOLING SYSTEM SERVICE
Drain, flush and refill system with new engine coolant.
Refer
to "Recommended Fluids and Lubricants" in
this section,
or ENGINE COOLING (SEC. 68).
TIMING BELT REPLACEMENT
Replacement of the timing belt is recommended at
every 60,000 miles (96,000 km).
Failure
to replace the timing belt may result in serious
damage
to the engine.
TIRE ROTATION
Rotate tires every 7,500 miles (12,000 km).
POWER STEERING FLUID REPLACEMENT
Drain the power steering fluid and then refill the
system
to the proper level with power steering fluid
after every 30,000 miles (48,000 km) of operation.
See the appropriate section
of this manual for further
details.
FRONT WHEEL HUBS LUBRICANT
REPLACEMENT
Clean and repack the front wheel bearings at 30,000
mile (48,000 km) intervals.
Clean and lubricate the free wheeling hubs at the
same
time the front wheel bearings are serviced.
Refer
to FRONT DRIVING AXLE (SEC. 4C).
RADIATOR CORE AND AIR CONDITIONING
CONDENSER CLEANING
Clean the front of the radiator core and air con­
ditioning condenser, at 60,000 mile (96,000 km)
intervals.
SPARK PLUG WIRE INSPECTION
Check the spark plug wires at 60,000 mile (96,000 km)
intervals.
..

FLUID LEVEL CHECK
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine
oil level -Check level and add if
necessary. The best time to check the engine oil
level is
when the oil is warm. After stopping the
engine with the vehicle on a level surface, wait a
few minutes for the oil to drain back to the oil pan.
Pull
out the oil level indicator (dipstick). Wipe it
clean and push the oil level indicator back down all
the
way. Pull out the oil level indicator, keeping the
tip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above
the
"ADD" mark and between the "ADD" and
"FULL" marks in the operating range area. Avoid
overfilling the engine since this may cause engine
damage. Push
the oil level indicator back down all
the
way after taking the reading.
If you check the oil level when the oil is cold, do
not run the engine first. The cold oil will not drain
back
to the pan fast enough to give a true oil level.
Engine coolant level and condition -Check
engine coolant level in the coolant reservoir and
add engine
coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level -Check washer
fluid level in reservoir and add if necessary.
Power steering system reservoir level-Check
and keep at
proper level.
Brake master cylinder reservoir level -Check
fluid. Keep fluid at proper level. A low fluid level
can indicate
worn disc brake pads which may need
to be serviced.
Hydraulic clutch system -Check fluid l~vel in
the reservoir.
Add fluid as required.
Battery fluid level -Check fluid level in the
battery.
FLUID LEAK CHECK
Check for fuel, water, oil or other fluid leaks by
looking at the surface beneath the vehicle after it
has been parked for a while. Water dripping from
the air conditioning system after use is normal. If
you notice gasoline fumes or fluid at any time,
locate the source and correct it at once.
ENGINE OIL AND OIL FILTER
REPLACEMENT
Always use API SE, SF, SG, SH or ILSAC GF-1
quality oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the
next oil change. Then, select the recommended oil
viscosity
from the chart (Fig. OB-1).
Always change the oil and the oil filter as soon as
possible after driving in a dust storm.
MAINTENANCE AND LUBRICATION OB-5
ENGINE COOLING SYSTEM INSPECTION
Inspect coolant/anti-freeze. If coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep
coolant at the proper mixture for proper freeze
protection,
corrosion inhibitor level and best engine
operating temperature.
Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose
clamps if equipped with screw-type clamps. Clean
outside of radiator and air conditioning condenser.
Wash
filler cap and neck. To help ensure proper
operation, a pressure test of both the cooling
system and cap is also recommended.
EXHAUST SYSTEM INSPECTION
Visually inspect the exhaust pipes, muffler, heat
shields and hangers
for cracks, deterioration, or
damage.
Be alert to any changes in the sound of the exhaust
system
or any smell of fumes. These are signs the
system may be leaking or overheating. Repair the
system at once,
if these conditions exist. (See also
"Engine Exhaust Gas Safety" and "Three Way
Catalytic Converter" in Owner's manual.)
FUEL CAP, FUEL LINES, AND FUEL TANK
INSPECTION
Inspect the fuel tank, the fuel cap and the fuel lines
every
60,000 miles (96,000 km) for damage which
could cause leakage.
Inspect the fuel cap and the gasket for correct sealing
and physical damage. Replace any damaged parts.
DRIVE BELT INSPECTION
Check the belts driving the steering oil pump, the air
conditioning compressor, and the generator
for
cracks, fraying, wear, and correct tension every 30,000
miles (48,000 km). Adjust or replace as necessary.
WHEEL ALIGNMENT, BALANCE AND
TIRES OPERATION
Uneven or abnormal tire wear, or a pull right or left
on a straight and level road may show the need for
a wheel alignment. A vibration of the steering
wheel or seat at normal highway speeds means a
wheel balancing is needed. Check tire pressure
when the tires are "cold" (include the spare).
Maintain pressure as shown in the tire placard,
which is located on the driver's door lock pillar.
STEERING SYSTEM OPERATION
Be alert for any changes in steering action. An
inspection
or service is needed when the steering
wheel is harder
to turn or has too much free play, or
if there are unusual sounds when turning or parking.

MAINTENANCE AND LUBRICATION OB-13
APPROXIMATE CAPACITIES
Items Metric Measure U.S. Measure
Fuel tank 85L 22.5 Gal.
*Crankcase
Oil Change with Filter .............................. 5.4L 5.7 at
Oil Change without Filter ••••••••••••••••••\
0 •••• 0 ••• 4.7L
5.0 at
Coolant ........................................ MIT 8.8L 9.3 at
A/T 8.5L 9.0 at
Transmission
Manual
.......................................... 2.95L 3.1 at
Automatic ••••••••••••••••••\
•• 0 •••• 0 0 0 ••••••••••• 8.6L 9.1 at
Transfer
1.45L 1.5 at
Axle
Rear o o o 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I 0 0 0 o o o o o o o 0 0 0 0 0 0 0 0 0 0 0 o o 1.8L 1.9 at
Front ........................................ ~ ... 1.5L 1.6 at
Power steering ••• 0 ••••••••• 0 ••••••••••••••••••\
0 •••• 1.0L 1.1 at
Air conditioning (R-134a) o o 0
0 0 0 0 0 0 0 0 I 0 0 0 0 0 o o 0 o 0 0 0 0 0 0 0 0.75kg 1.651b
* Crankcase capacities shown are approximate refill capacities.
After
refill, recheck oil level.

ENGINE DIAGNOSIS 6-9
ENGINE LACKS POWER (Cont'd)
Condition Possible cause Correction
Engine overheating
Level of Engine Coolant too low Replenish
Thermo switch or fan motor 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 Change or replenish
or
wrong oil engine
Resistance in exhaust system
Clean exhaust system or
increased replace
defective parts
Throttle Position Sensor adjustment Adjust
Wide Open Throttle
incorrect switch setting
Throttle Position Sensor circuit open
or Correct or replace
shorted
Cylinder head gasket damaged Replace
Engine overcooling
Radiator
overcooling Install cover
in front of
radiator
Thermostat defective Replace
(Use a thermostat set
to open at a2·c (180.F))
Engine
lacks compression Refer to Hard Start
Others Tire inflation pressure
abnormal Adjust to recommend
pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level
of oil in engine crankcase too Correct level of engine oil
high
Exhaust Gas
Recirculation Valve Replace
defective
Back pressure transducer defective
Replace

EJ REMOVAL
Preparation: • Remove engine hood.
• Drain radiator Engine Coolant.
• Disconnect battery ground cable.
1. Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Radiator fan assembly
• Remove four nuts, then the radiator fan
assembly.
4. Accelerator Pedal cable
• Disconnect from throttle body and cable
bracket.
5. Canister vacuum hose
6. Vacuum booster hose
• Disconnect from common chamber.
7. Connectors
• Disconnect from Manifold Absolute Pressure,
canister Vacuum Switching
Valve (VSV),
Exhaust Gas Recirculation VSV,
Intake Air
Temperature and ground cable.
8. High tension cables
• Disconnect from cylinder head cover.
9. Ignition Control Module assembly
• Disconnect three Electronic Ignition con­
nectors.
• Remove three Electronic Ignition bracket fixing
bolts, and remove Electronic Ignition assembly
with high tension cables.
10. Throttle body
• Remove four fixing bolts.
11. Vacuum hoses
• Disconnect vacuum hoses on canister VSV and
Exhaust Gas Recirculation VSV
from the
throttle body.
12. Positive Crankcase Ventilation hose
• Disconnect from common chamber.
13. Fuel Pressure Control Valve vacuum hose
• Disconnect from common chamber.
14. Evaporative Emission Canister Purge hose
• Disconnect from common chamber.
15. Exhaust Gas Recirculation assembly
16. Common chamber
• Remove six bolts, two nuts and four bracket
fixing bolts, then remove the
common
chamber.
17. Throttle body
• Disconnect Engine Coolant hose from throttle
body.
• Disconnect Idler Air Control Valve and Throttle
Position Sensor connectors.
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-43
18. Fuelhoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove two bracket fixing bolts on
the cylinder head cover.
19. Fuel injector connectors
• Disconnect connectors from injectors.
• Disconnect thermo sensor connector.
20. Intake manifold
• Remove two fixing bolts and four nuts.
21. Engine Coolant manifold
• Disconnect heater hose.
• Remove four fixing bolts.
22. Power steering pump drive belt
23. Air Conditioning compressor drive belt
24. Generator drive belt
25. Power steering pump
26.
Fan pulley assembly
27. Crankshaft pulley assembly
~ • Using special tool J-8614-01, hold crankshaft
~ pulley.
•
Remove center bolt, then the pulley.
28. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing
belt cover.
29. Timing belt cover
30. Pusher
\fl CAUTION:
VI The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
31. Timing belt
\fl CAUTIONS:
VI 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 30mm.
2) Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the belt life.
3) Do not attempt to pry or stretch the belt with a
screwdriver
or any other tool during
installation.
4) Store timing belt in a cool and dark place.
Never expose the
belt to direct sunlight or
heat.
32. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
33. Power steering pump bracket
• Disconnect ground cable from bracket.
• Remove five fixing bolts, then the bracket.
34. Exhaust front pipe
35.
Level gage guide tube fixing bolt
• Remove from cylinder head.
36. Cylinder head

'.:.:.
6A1-44 ENGINE (V6 3.2L DOHC AND SOHC)
1••1 INSTALLATION
36. Cylinder head
l"i:a\1 • Using special tools, tighten fixing bolts to the
~ specified torque, in sequence shown in
Fig.
6A 1-53.
Extension wrench: J-39252
Extension wrench: J-24239-01
NOTE:
• Do not reuse cylinder head gasket and M11
fixing bolts.
• Do not apply the oil to the bolt.
M8x1.25
1~1 Torque N·m (lb·ft)
M11x1.5
21 (15)
~~~ Torque N·m (lb·ft) 64 (47)
[ill ® ® @ , , , I I I
~
I
I I
I I
I I I
I I
I I I
I I
I

0
' , , ' ' , ' , ' ® '-~ CD @
M8 Bolt QM11Bolt
Fig. 6A1-53
35. Level gage guide tube fixing bolt
34. Exhaust front pipe
' '
, ,
(j)
I
I
I
@
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 67 (48)
33. Power steering pump bracket
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 46 (34)
32. Cylinder head cover
• Refer to "Cylinder head cover removal and
installation" in this section.
31. Timing belt
• Refer to "Timing belt removal and installation"
in this section.
30. Pusher
• Tighten bolt to the specified torque.
1~1 Torque N·m (lb·ft) I 19 (14)
29. Timing belt cover
• Remove crankshaft pulley that was installed in
step
33.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
28. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
~ specified torque.
Torque
N·m(lb·ft) I 18(13)
27. Crankshaft pulley assembly
l"i:a\1 • Using special tool J-8614-01, hold the
~ crankshaft pulley.
~~~· Tighten center bolt to the specified torque.
Torque
N·m (lb·ft) I 167 (123)
26. Fan pulley assembly
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
25. Power steering pump
~ • Tighten pump fixing bolts to the specified
~ torque.
Torque
N-m (lb·ft) 46 (34)
24. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
23. Air Conditioning compressor drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
22. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
21. Engine Coolant manifold
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) J 22 (16)
• Connect heater hose.
20. Intake manifold
~ • Tighten fixing bolts and nuts to the specified
~ torque.
Bolts
Torque N-m (lb·ft) 24 (17)
Nuts
Torque
N-m (lb·ft) 24 (17)
19. Fuel injector connectors
• Connect to each injector.
18. Fuelhoses
• Connect the hoses securely and install the bolts
on the head cover.
17. Throttle body
..

~:· T·, ·.}:
6A1-48 ENGINE (V6 3.2L DOHC AND SOHC)
33. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
34. Power steering pump bracket
• Disconnect ground cable from bracket.
35.
• Remove five fixing bolts, then the bracket.
Exhaust front pipe
36.
37. Level gage fixing bolt
• Remove from cylinder head.
Cylinder head
1••1 INSTALLATION
37. Cylinder head
li0\1 • Using special tools, tighten fixing bolts to the
~ specified torque, in sequence shown in Fig.
6A1-56.
~ Extension wrench: J-39252
t:6.l Extension wrench: J-24239-01
NOTE:
• Do not reuse cylinder head gasket and M11
fixing bolts.
•
Do not apply the oil to the bolt.
M8x1.25
Torque
N·m (lb·ft) 21 (15)
M11x1.5
Torque
N·m (lb·ft) 64 (47)
OJ] ® ® ® , ' ' ,
, I , ,
[IQJ ' I I
I I
I I I
I I
I I I
I I
,
[I] ' , , ' @ ' ,
CD ' , , __
@
[[ M8 Bolt (J M11 Bolt
Fig.
6A1-56
36. Level gage guide tube fixing bolt
35. Exhaust front pipe
'
,
(])
I
I
I
,
@
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 67 (49)
34. Power steering pump bracket
~~~ • Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 46 (34)
33.
32.
31.
Cylinder head cover
• Refer to "Cylinder head cover removal and
installation" in this section
Timing belt
• Refer to "Timing belt removal and installation"
in this section.
Pusher
• Tighten bolt to the specified torque.
I~I __ T_o_r~qu_e __ N_·_m~(lb_·ft_)~ ______ 1_9_(1_4_) ____ _
30. Timing belt cover
• Remove crankshaft pulley that was installed in
step 34.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
29. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
t:6.l specified torque.
Torque
N·m (lb·ft) I 18 (13)
28. Crankshaft pulley assembly
li0\1 • Using special tool J-8614-011 hold the
~ crankshaft pulley.
~~~ • Tighten center bolt to the specified torque.
Torque
N·m (lb·ft) I 167 (123)
27. Fan pulley assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
26. Power steering pump
~ • Tighten pump fixing bolts to the specified
t:6.l torque.
Torque
N·m (lb·ft) I 46 (34)
25. Generator drive belt
• Refer to Section 68 "Drive belt adjustment".
24.
Air Conditioning compressor drive belt
• Refer to Section 68 "Drive belt adjustment".
23. Power steering pump drive belt
• Refer to Section 68 "Drive belt adjustment".
22. Engine Coolant manifold
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
• Connect heater hose.
21.
Intake manifold
~ • Tighten fixing bolts and nuts to the specified
t:6.l torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
..

Mixing ratio(%) 0 10 20 30 40 50
~
' -10
'
1
' -30

~ -40
In case of 8.5 lit total cooling system capacity
Mixing Anti-freeze
Water: solution: ratio (%) lit. (U.S. gal) lit. (U.S. gal.)
0 0 0
8.5 (2.2) 10 0.9 (0.3) 7.6 (2.0) 15
1.3 (0.4) 7.2 (1.9) 20 1.7 (0.5) 6.8 (1.8)
25 2.1 (0.6) 6.4 (1.7) 30 2.6 (0.7) 5.9 (1.6)
35 3.0 (0.8) 5.5
(1.5) 40 3.4 (0.9) 5.1 (1.3)
45 3.8 (1.0) 4.7 (1.2) 50 4.3 (1.1)
4.2 (1.1)
Fig. 68-5
ENGINE COOLING 68-3
• Mixing ratio
Check
the specific gravity of engine coolant in the
cooling system temperature ranges from oo C to
50° C using a suction type hydrometer, then deter­
mine the densityofthe Engine Coolant by referring
to the table. (Fig. 68-6)
1,100 1'-........ ........ ...... .............. Mixing ratio
~"""--r-... 1'-""' 1,1)90
........ ...... ........ ........ .......... '
1,000
'"" 1,07 o......_ 1'-........ I'-.......... I"-........ .......
I"-........ ..........
................. I"-........
'
1,080
....... I"-........ ~ ........ ......
........ "'" ~"""--r--..... 1,050
r-. ........ ~ .......... ......
---
........ ........ 1,040
r-.... !'--.. 1'-0 '"" ~"""--1'-.... ........ 1,03
1--....... ........ r--~ ........
'
1,020
....... ~ 1'-0 ~"""---.... 1,01
...... ,
'
1,000
10 20 30 40 50 60 70 Coolant temperature ("C)
Fig. 68-6
DIAGNOSIS
ENGINE COOLING TROUBLE
Condition Possible cause Correction
Engine
overheating Low Engine Coolant level Replenish
Thermo unit faulty Replace
Faulty
thermostat Replace
Faulty
Engine Coolant unit Repair or replace
Clogged
radiator Clean or replace
Faulty
radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to Faulty thermostat Replace
warm-up Thermo unit faulty Replace

68 - 4 ENGINE COOLING
ON-VEHICLE SERVICE
DRAINING AND REFILLING COOLING
SYSTEM
Before draining the cooling system, inspect the sys­
tem and perform any necessary service to ensure that
it is clean, does not leak and is in proper working
order. The Engine Coolant (EC) level should be be­
tween the "MIN" and "MAX" lines of reserve tank
when the engine is cold. If low, check for leakage and
add
EC up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator
cap
or radiator filler hole, and the EC should also be
free
from oil. Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening
the drain petcock at the bottom of the radiator.
2. Remove the radiator cap.
W WARNING
To avoid the danger of being burned, do not
remove the cap while the engine and radiator
are still hot. Scalding fluid and steam can be
blown out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.
WATER PUMP
3
j
2
4. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze but no
more than 70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the
engine is cold.
6. Block the drive wheels and firmly apply the park­
ing brake.
Shift an automatic transmission to "P"
(Park) or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and
warm it up at 2,500 -3,000 rpm for about 30
minutes.
8. When the air comes out from the radiator filler
neck and the EC level has gone down, replenish
with the EC. Repeat this procedure until the EC
level does not go down. Then stop the engine and
install the radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with EC up
to the "MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound
from the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 7
to 10.
Removal steps
1. Timing
belt 2. Idle pulley 3. Water pump assembly
4. Gasket
Installation steps To install, follow the removal steps in the reverse order.
Fig. 6B-7
•