Cooling System

ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work. . . . . . . . . . . . . . . 1B-2
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
A List of Defective Phenomena . . . . . . . . . . . . . 1B-8
Main Data and Specifications. . . . . . . . . . . . . . . 1B-8
Water Pump (4HK1) . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-12
Water Pump (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1B-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-27
Cooling System
Cooling System 1B-
1B-2 Cooling System

Cooling System
Precautions on Service Work Explanations on functions and operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components.
cover the cap with a thick cloth when the cooling water
is cool, release the pressure by slowly turning the cap,
and then remove the cap.
4HK1

Name
1. Water Jacket 10. Reservoir Tank
2. Drain Plug 11. Air Bleeding Plug
3. Oil Cooler 12. Water Outlet Pipe
4. Water Pump 13. Thermostat (2 units)
5. Drain Cock 14. Thermometer Unit
6. Radiator 15. Bypass Route
7. Cooling Fan 16. Turbocharger
8. Radiator Cap 17. EGR Cooler
9. Heater Core
 Cooling System 1B-3
6HK1

Name
1. Water Jacket 8. Radiator Cap
2. Drain Plug 9. Reservoir Tank
3. Oil Cooler 10. Water Outlet Pipe
4. Water Pump 11. Thermostat (2 units)
5. Drain Cock 12. Thermometer Unit
6. Radiator 13. Bypass Route
7. Cooling Fan 14. EGR Cooler
1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.

* 4HK1 is shown for illustration.

Name
1. Fan Center 3. Impeller
2. Bearing 4. Seal Unit
 Cooling System 1B-5
Thermostat
The thermostat is a wax pellet type and consists of two
units, in which one unit (bottom bypass type) has an
valve initial opening temperature of 82 C (180 F) and
the second (inline type) has an valve initial opening
temperature of 85 C (185 F). It is designed such that
the water temperature can be adjusted finely and it is
mounted within the thermostat-housing unit.

Name
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve

Function Check 6HK1

Cooling water level check Standard value
• Check the cooling water level within the reserve Cooling water 14.5 L (15.3 qts)
tank and the level is appropriate when the cooling level (Engine only)
water level is within the MAX (upper limit) and MIN
(lower limit) range. In case the volume of the
Inspection
cooling water is deficient, remove the reserve tank
cap and replenish with a mixture of tap water and Cooling water leak check
engine coolant in the ratio of 1:1 until the level • Use the radiator cap tester and apply a pressure of
comes close to the MAX line. 200 kPa (29.0 psi) and check for leaks in the
4HK1 locations given below. Check that the radiator hose
and heater hose are not damaged or degraded
Standard value and the hose clamp is not loose.
Cooling water 14 L (14.8 qts)
level (between MIN and MAX levels)
1B-6 Cooling System
Inspection location
• Radiator ASM, water pump ASM, radiator hose,
heater hose

Coolant
1. About the engine coolant concentration
• Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the
concentration of the engine coolant.
• Use only genuine engine coolant.
• Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.

Name
1. Antifreeze Hydrometer
2. Radiator

• Fix the temperature of the cooling water being

measured in the range of 0 to 50 C (32 to 122 F).
• Measure the temperature and specific gravity and
determine the concentration from the table given
below.

Freezing Mix ratio Concentration

temperature Liter (qts) of engine
guideline coolant
Engine Tap
coolant water
-18 C (-0.4 F) 4.2 (4.4) 7.8 (8.2) 35%
-25 C (-13 F) 5.0 (5.3) 7.0 (7.4) 42%
-35 C (-31 F) 6.0 (6.3) 6.0 (6.3) 50%
-40 C (-40 F) 6.4 (6.8) 5.6 (5.9) 53%

2. Engine coolant density measurement

Methods for measuring specific gravity
• Measure the specific gravity and the temperature
of the cooling water using an anti-freeze specific
gravity meter and thermometer.
Take precautionary measures as the boiled cooling
water may gush out at high temperatures if the cap
is removed.
• Use a deep container to suit the height of the Coolant scooping method
specific gravity meter. • Measure the concentration using the coolant scoop.
 Cooling System 1B-7
EGR cooler air bleeding procedure
When replacing the coolant, bleed air from the EGR
cooler with the following procedure.
Caution:
Be sure to replace the coolant when it is cooled.
Loosen the air bleeder plug (1) on the EGR cooler.

3. Pour coolant into the radiator via its opening.

4. Tighten the plug when the coolant spills over from
the air bleeder plug.
• Replace the copper packing if it is faulty.

Caution:
• Take care to prevent the spilt coolant from getting
the exhaust system parts wet.
• Be sure to wipe off the spilt coolant.
Tightening torque: 24.5—30.5 N m (2.5—3.1 kg m/
18—23 lb ft)
• Pour coolant into the radiator via its opening again
until it is filled.
• Bleed air from the engine body coolant with idling
the engine.
1B-8 Cooling System
A List of Defective Phenomena
• Engine overheats
• Engine overcools

Engine overheats

Condition Possible Cause Correction

Engine overheats Cooling water volume is deficit. Replenish.
Thermometer unit is defective. Replace.
Thermostat is defective. Replace.
Radiator pump is defective. Replace.
Radiator is clogging. Clean or replace.
Radiator cap is defective. Replace.
Engine oil volume is deficient or Replenish or change the engine oil.
incorrect engine oil is used.
Cylinder head gasket is defective. Replace.
The fan belt is loose. Adjust.
Exhaust system is clogging. Clean or replace.
The fuel injection quantity is in surplus. Diagnose the engine control system.
Fuel injection timing is incorrect. Diagnose the engine control system.
Starting pressure of fuel injection is Diagnose the engine control system.
low.

Engine overcools

Condition Possible Cause Correction

Engine overcools Thermostat is defective. Replace.

Main Data and Specifications

Water pump Centrifugal impeller system

Pulley ratio 0.950
Thermostat Wax pellet system
Valve opening temperature C ( F) With jiggle valve 85 (185)
Without jiggle valve 82 (180)
Temperature when fully open C ( F) With jiggle valve 100 (212)
Without jiggle valve 95 (203)
 Cooling System 1B-9

Water Pump (4HK1)

Components

Name
1. Fan 4. Fan Belt
2. Spacer 5. Water Pump ASM
3. Water Pump Pulley 6. Gasket

Removal
1. Drain the coolant.
2. Remove the four mounting bolts and then the fan
ASM and spacer, water pump pulley.
1B-10 Cooling System

Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 5. Remove the gasket.
4. Bolt

3. (2) and (3) that tighten the setting plate and water Inspection
pump together. Loosen the adjusting bolts (1) in 1. Appearance check
the generator and remove the fan belt. • Check for cracks or damage in the pump body.
• Check for cracks and corrosion in the impeller.
• Check for water leakage from the seal unit.
• If you find abnormalities, replace with the water
pump ASM.
2. Bearing nut check
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
• If you find abnormalities, replace with the water
pump ASM.

Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt

4. Remove the water pump ASM while inserting and

scraping with the driver at the position shown in
the figure.
 Cooling System 1B-11
Installation
1. Install the gasket.
2. Install the water pump ASM.
• Mount the water pump to match with the studs
of the front cover.
3. Temporarily fit the bolts until the water pump pulley
and the spacer and fan are properly seated in the
water pump ASM.
4. Mount the fan belt, tighten the adjusting bolts of
the generator, and adjust the tension.
• Refer to the “Drive Belt”.
5. After fan belt adjustments, tighten the generator
using the specified torque.

Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt

7. Pour coolant.

Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt

6. After the fan belt adjustments, tighten the

temporarily fitted fan pulley and spacer and fan
using the specified torque.
Tightening torque:
M8: 24 N m (2.4 kg m/18 lb ft)
M10: 45 N m (4.6 kg m/33 lb ft)
1B-12 Cooling System
Torque Specifications
 Cooling System 1B-13

Water Pump (6HK1)

Removal • Loosen the mounting bolt (2) and the sliding

piece nut (1).
1. Loosen the fan fixing nuts to remove the cooling
fan. • Pivot the alternator at the mounting bolt toward
the center of the engine.

2. Remove the fan guide.

Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide

3. Loosen the fan pulley fixing bolts.

4. Remove the fan belt.
1B-14 Cooling System
5. Remove the adapter and fan pulley.

Name
1. Adapter 4. Bypass hose
2. Fan pulley 5. Water duct
3. Water pump 6. Water duct

6. Disconnect the bypass hose.

7. Loosen the fixing nuts and bolts from the water
pump.
8. Remove the water pump from the front plate.
9. Discard the gaskets.
 Cooling System 1B-15
Installation 6. Clamp the bypass hose.
1. Install the water pump with new gaskets to the 7. Install the fan pulley and adaptor to the water
front plate. Use the locating pin. pump.
Tighten the fixing bolts to the specified torque.
2. Tighten the fixing nuts and bolts to the specified
torque. Tightening torque: 52 N m (5.3 kg m/38 lb ft)
Tightening torque:
Nut A: 39 N m (4.0 kg m/29 lb ft)
Bolt: 20 N m (2.0 kg m/15 lb ft)

8. Install the fan belt.

9. Adjust the fan belt tension.
• Depress the drive belt midway between the
3. Install the water duct with new gasket to the alternator and fan pulley.
cylinder head.
Tighten the bolts to the specified torque. Drive Belt Deflection: 8 - 11 mm (0.31 - 0.43 in)

Tightening torque:
Bolt (1) : 221.6 N m (22.6 kg m/163 lb ft)
Bolt (2) : 24.5 N m (2.5 kg m/18 lb ft)

4. Install the water duct with new gasket to the oil

cooler and water pump.
Tighten the bolts to the specified torque.
Tightening torque: 20 N m (2.0 kg m/15 lb ft)
5. Connect the bypass hose.
1B-16 Cooling System
10. Install the cooling fan.
Tighten the fixing nuts to the specified torque.
Tightening torque: 52 N m (5.3 kg m/38 lb ft)

11. Install the fan guide.

Tighten the fixing bolts to the specified torque.
Tightening torque: 30 N m (3.1 kg m/22 lb ft)

Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
 Cooling System 1B-17
Torque Specifications
1B-18 Cooling System
Disassembly

Name
1. Center 9. Shaft
2. Dust cover 10. Water pump body
3. Snap ring 11. Dowel pin
4. Bearing 12. Seal unit
5. Bearing 13. Impeller
6. Spacer 14. Gasket
7. Bearing 15. Cover
8. Washer 16. Bolt
 Cooling System 1B-19
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover 1-8521-0062-0 to remove the Make the necessary adjustments, repairs and part
impeller from the water pump. replacements if excessive wear or damage is
3. Use a puller to remove the water pump center. discovered during inspection.
4. Remove the dust cover and snap ring.
Water pump impeller
5. Remove the water pump shaft with ball bearings.
• Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.

Water pump shaft

6. Use a bench press to remove the bearing from the
shaft. 1. Measure the water pump shaft and center or
impeller interference.
If the measured interference is less than the
specified limit, the pump shaft and / or the center
and impeller must be replaced.
Pump shaft and center interference:
Limit: 0.048 – 0.078 mm (0.0019 – 0.0031 in)
Pump shaft and impeller interference:
Limit: 0.022 – 0.062 mm (0.0009 – 0.0024 in)

7. Remove the seal unit.

1B-20 Cooling System
2. Carefully wipe away any bearing grease. • Use a bench press to gradually press the water
3. Listen for excessive bearing operating noise. pump shaft down until the bearings are seated
correctly.

Excessive bearing operating noise indicates

severe bearing wear. 2. Install the water pump shaft with bearings to the
water pump body.
• Repack the bearings with multipurpose grease.
Reassembly
1. Install the ball bearing to the water pump shaft.
• Apply engine oil to the water pump shaft.
• Place the water pump shaft and the bearings
on the base plates.
• Install the washer (4), ball bearing (3), spacer
(2), and bearings (1).

• Place the water pump body on bench press

base plate.

NOTE :
To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and
the water pump shaft.
 Cooling System 1B-21
• Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body.
water pump body. • Press in the seal unit to the specified position
• Use a bench press to gradually press the water using a bench press and installer 1-85220-047-
pump shaft into the water pump body. 0.
Seal unit installation position A:
NOTE :
11.0 – 11.6 mm (0.433 – 0.457 in)
Do not drive the bearing into position with a hammer or
similar object. Bearing damage will result.

5. Install the water pump impeller to the water pump

3. Install the snap ring and dust cover. shaft.
• Use pliers to install the snap ring into water • Use a bench press to press in the impeller.
pump body groove. • The impeller must be flush with the water pump
• Install the dust cover with the flange facing out. shaft end.
6. Use a bench press to gradually press the water
pump center onto the water pump shaft to the
specified dimension.

Dimension A: 202.9 mm (7.988 in)

7. Install the rear cover with new gasket to the water
pump body.
1B-22 Cooling System
Special tool

Illustration Tool Number/Description

1-8521-0062-0
Impeller remover

1-8522-0047-0
Seal unit installer
 Cooling System 1B-23

Thermostat
Components

* 4HK1 is shown for illustration.

Name
1. Water Outlet Pipe 3. Gasket
2. Thermostat

Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Disconnect the water outlet pipe.
3. Remove the thermostat.
4. Remove the gasket from the thermostat.

Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
• Measure the temperature when the valve is just
opened and when it is fully open.
1B-24 Cooling System
Installation 6HK1
1. Mount the gasket on the thermostat and mount it at
the position shown in the figure.
• The thermostat with the jiggle valve (A) is
installed to the left side of the engine. The jiggle
valve faces the rear of engine.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.

Name
1. Thermostat

2. Connect the water outlet pipe.

Tightening torque: 24 N m (2.4 kg m/18 lb ft)

4HK1

* 4HK1 is shown for illustration.

3. Replenish the cooling water stored during the
discharge, and check the volume of the cooling
water.
Name
1. Thermostat
2. Cylinder Head
 Cooling System 1B-25

Drive Belt
Components

Name
1. Crankshaft Pulley 5. Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Adjusting Plate
4. Generator 8. Water Pump Pulley

Inspection Drive Belts Adjustment

Check for the presence of wear or damage in the drive Adjustment procedure
belt and renew the parts if necessary. Adjust simultaneously the generator drive belt for
Check the tension of the belt and adjust if necessary. adjustment of belt.
Inspection procedure 1. Loosen the adjusting plate lock nuts and the
Apply a pressure of 98 N (22 lb) at the center of the mounting bolts of generator on the underside of
long span of each belt and check the deflection of the the generator.
belt. 2. Rotate the adjusting bolts of generator and adjust
the belt (remove and fit).
Deflection of generator drive belt
• When replacing the belt, you must always
When the belt is new replace both the belts.
5.0 to 5.8 mm (0.19 to 0.23 in) 3. After adjustments, tighten the adjusting plate lock
When the belt is reused nuts and the mounting bolts of generator on the
6.1 to 6.9 mm (0.24 to 0.27 in) underside of the generator using the specified
torque.
Tightening torque:
Lock nut: 76 N m (7.7 kg m/56 lb ft)
Bolt: 127 N m (13.0 kg m/94 lb ft)
1B-26 Cooling System

Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt
 Cooling System 1B-27
Torque Specifications

* 4HK1 is shown for illustration.

1B-2 Cooling System