2004 ISUZU TF SERIES radiator

ENGINE MECHANICAL 6A – 135


INTER COOLER
REMOVAL AND INSTALLATION





RTW46ALF001001

Removal Steps
1. Radiator grille
2. Front bumper fascia
3. Front bumper inpact support assembly
4. Inter cooler

Installation Steps
4. Inter cooler
3. Front bumper inpact support assembly
2. Front bumper fascia
1. Radiator grille

6A – 136 ENGINE MECHANICAL





RTW36ASH000601
Removal
1. Radiator Grille

Refer to removal procedure in Sheet Metal section.







RTW36ASH000501
2. Front Bumper Fascia

Remove the nine clips and four screws.

Disconnect the fog light harness connectors.
















RTW46ASH002101
3. Front Bumper Impact Support Assembly

Remove the nut and two bolts.



4. Inter Cooler

Remove the nut and two bolts.

Disconnect the air hose.




Installation
4. Inter Cooler

Tighten the nut and two bolts.


3. Front Bumper Impact Support Assembly

Tighten the nut and two bolts.



2. Front Bumper Fascia

Install the nine clips and four screws.

Connect the fog light harness connectors.


1. Radiator grille

Refer to installation procedure in Sheet Metal section.

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.

6B – 6 ENGINE COOLING



110RS001
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3

122.7 kPa (13.5

17.8 psi) pressure. (No oil cooler provided for M/T)





F06RW005
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system
capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC
See section 0B MAINTENACE AND LUBRICATION.





PTW46BSH000201
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE

ENGINE COOLING 6B – 7
DIAGNOSIS
Engine Cooling Trouble
Symptom Possible Cause Action
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change 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
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace

6B – 8 ENGINE COOLING
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolan
t
(EC) level should be between the “MIN" and “MAX" lines o
f
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.


P1010064
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.

2. Remove the radiator cap.
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 unde
r
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.
4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.
 Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the radiato
r
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to reduce
the pressure when the coolant has become cooler.