COOLING

SYSTEM
GENERAL ................................................................................ CL - 2
COOLING FAN ......................................................................... CL - 9
INSPECTION AND ADJUSTMENT OF V-BELT TENSION ...... CL-10
WATER PUMP .......................................................................... CL-11
THERMOSTAT ......................................................................... CL-12
WATER TEMPERATURE GAUGE UNIT,
ENGINE OVERHEAT SWITCH ................................................ CL-13
RADIATOR ............................................................................... CL-15
GAS LEAK TEST ..................................................................... CL-17
BLEEDING THE COOLING SYSTEM ...................................... CL-17
CL-2 COOLING SYSTEM

GENERAL
SPECIFICATIONS

Model
Item D4AF, D4AE, D4AL, D4DA, D4DB
Cooling method Water-cooling, forced circulation
Coolant capacity Truck : 13 lit
Bus : 28 lit (with freeheat)
19 lit (without freeheat)

Water pump Type Volute pump

Drive V-belt
V-belt Type x q'ty <With power steering>
Raw edge plain A Type x 2

Thermostat Type/valve opening temperature Wax-pellet, bottom bypass

(with jiggle valve) / 82°C
Fan Type Polypropylene, suction
Autocool fan coupling Type Viscosity
Hydraulic fluid Silicone oil

Radiator Type Tube-and-corrugated-fin

Cap Type Pressure type
GENERAL CL-3

SERVICE STANDARDS

Nominal value Correction and

Description (Basic diameter in [ ]) Limit remarks
Water pump Interference between pump shaft and flange [17] 0.08 to 0.10 Reassembly Replace
is permitted
Interference between pump shaft and impeller [13] 0.03 to 0.06 up to twice
Pump case to impeller installed dimension 20.8 to 21.7 Replace
Thermostat Valve opening temperature 80 to 84°C Replace
Valve lift/temperature 10 or more/95°C Replace
Radiator Pressure cap opening Norminal pressure 81 to 108 kPa Replace
presssure (0.83 to 1.10 kgf/cm²)

Negative pressure 4.9 kPa

(0.05 to kgf/cm²) or less

Radiator check pressure 135 kPa Replace

(1.4 kgf/cm²)

Reservoir tank inner pressure 49kPa(0.5kgf·cm2) Replace

V-belt deflection Between alternator and water pump 12 to 16 Adjust
Between power steering oil 4 to 6 Adjust
pump crankshaft

Between air conditioner 10 to 15 (D4AL, D4AF, D4AE) Adjust

compressor and tension pulley 16 to 20 ((D4DA, D4DB)

TIGHTENING TORQUE TABLE

Thread size Tightening torque Remark

Description
O.D. x pitch mm N·m (kgf·m)
Autocool fan coupling Fan mounting nut M6 x 1.0 5(0.5)
Fan coupling mounting M8 x 1.25 21(2.1)
Fan mounting nut M8 x 1.25 21(2.1)
Radiator Fan shroud mounting M6 x 1.0 5~7(0.5~0.7)
Radiator mounting M8 x 1.25 12~15(1.2~1.5)
Reservoir tank mounting bolt M8 x 1.25 9~14(0.9~1.4)
Water temperature gauge unit M16 x 1.5 20~25(2.0~2.5)
Alternator mounting bolt M12 x 1.25 91 (9.3)
Alternator adjusting bolt M12 x 1.25 82 (8.4)
CL-4 COOLING SYSTEM

TROUBLESHOOTING

Overheat

No Adjust the tension of the belt and after checking

Normal tension in V-belt?
the belt, replace it if necessary.
Yes

No Replenish the coolant.

Adeguate coolant level?
If there is a leak, drain the coolant quickly.
Yes

Yes Clean the radiator core and adjust deformation

Is there any clogged radiator fan?
if there is.
No

Yes
Imbued coolant? Clean the cooling system
Yes

No
Thermostat works properly? Replace the thermostat.
Yes

No
Water pump works properly? Replace the water pump
Yes

Yes
Any oil-leak in autocool fan coupling? Replace the fan coupling
No

Check the possible causes of overheating

GENERAL CL-5

Quick loss of coolant

Yes Yes
Any leakage from radiator Loose hose connection? Tighten clampes
hose? No
No

Cranked or damaged Yes

Replace the hose
hose?
Any leakage from radiator
core? Yes
Connect or replace the radiator
No

Yes
Any leakage from Replace O-ring
water pump?
No

Any leakage from Yes

radiator pressure valve?
No
• Connect pressure range
in pressure valve? No
Replace the pressure valve
• Gasket in good
condition?
Yes

Any leaked gas from cyl-

Yes
inder head gasket in Replace the cylinder head gasket
Any leakage from coolant?
oil cooler?
No
Yes
No
Are bolts tightened properly? Tighten bolts
Yes
Check the possible leak-
ing spots in engine.

Yes
Defective O-ring? Replace
CL-6 COOLING SYSTEM

DESCRIPTION

<D4AF, D4AE, D4AL> <D4DA, D4DB>

Radiator Thermostat Radiator Thermostat

Oil cooler Oil cooler

Water pump Water pump

Drain plug Drain plug

Cooling fan Cooling fan

Drain cock
Drain cock

JCW25001

The engine is cooled by forced circulation of coolant by the water pump.

The illustrations show the coolant flow.

Water Pump Timing gear case From thermostat

Impeller
Of a centrifugal type, the water pump is driven by the V-belt from
the crankshaft pulley. From radiator
Coupling plate
A unit seal is installed between the impeller and water pump that (Vehicle with To
autocool fan crankcase
prevents leakage of coolant. There is a drain hole provided at the coupling)
bottom of the water pump case, which ensures that water should
leak from the unit seal, does not enter bearings. Unit seal

Water pump case Drain hole

The water pump is mounted on the timing gear case provided with D4AF0289

a suction pipe and swirl chamber.

Pressed into the one end of water pump shaft is the impeller with
backed blades which feeds coolant under pressure into the engine.

Thermostat At low
To radiator temper- At high
The thermostat, of a bottom bypass configuration, has a valve con- temperature
ature
trolled by a special wax enclosed in a pellet. The wax changes
from solid to liquid as it is heated, involving volumetric change for
regulating the flow of coolant.
The changes in valve position with varying coolant temperatures
From
regulate the flow rate of coolant into the radiator and water pump
cylinder head
(bypass side), thus controlling coolant temperature. To water pump D4AF1720

Ajiggle valve is installed in the thermostant.

GENERAL CL-7

The jiggle valve is normally in the lower position. Air in the engine <At stop> <At running>
is led to radiator through the clearance between the jiggle valve
and the breather hole, which permits easy supply of coolant. Aire Aire
When the engine is started and coolant flows, the jiggle valve is
pushed up to close the breather hole. Water pressure

Therefore, coolant cannot flow into the radiator until the tempera-
ture rises enough to open the thermostat valve. This contributes to
a shorter engine worm up time. CW25-005

Radiator
The radiator, with a tube-and-corrugated-fin type core, not only
cools the engine coolant but also separates vapor from liquid wa-
ter and regulates pressure in the cooling system.
The radiator is of a simple closed type equipped with a pressure
cap. The reservoir tank is open to atmostphere. The coolant over-
flowing from the radiator is therefore stored in the reservoir tank,
maintaining the radiator full with coolant at all times. CW25-006

Pressure cap Pressure building-up

The pressure cap regulates the pressure in the cooling system. Pressure spring
When the pressure builds up exceeding the predetermined level,
the pressure valve compresses the pressure spring relieving the
excessive pressure to the atmosphere.
To reservoir
As the coolant temperature falls forming a vacuum in the radiator, tank
the vent valve opens to admit air into the radiator, thus preventing
the radiator from being deformed by the vacuum.

Vacuum

From reservoir
tank

Vent valve

D4AF0295

Autocool Fan Coupling Working area

The autocool fan coupling is the device to control the fan speed Silicon oil
storage area Case
according to the engine coolant temperature. The bimetal detects
the air temperature running through the radiator and varies the Valve
Shaft
fluid coupling flows to control the fan speed. When the air tempera- Bimetal
ture rises, both ends of the bimetal are deformed to open the res-
Ball bearing
ervoir valve. Introduced fluid(silicone oil) here increases the fric-
tion force between the coupling case and rotor and the fan mounted Cover
to the case is driving at the similar speed of shaft. When the air Drive disc EDAC001A

temperature falls, the bimetal is operated to close the valve and

the fluid returns to the reservoir. It results in a quick speed de-
crease by sliding between the coupling case and rotor.
CL-8 COOLING SYSTEM

The air temperature running through the radiator

<At High Temperature> <At Low Temperature>

Valve
Valve close
open

EDAC002A

Engine coolant over heat warning system

When the engine is overheated, the warning lamp illuminates and buzzer sound is heard.
When the parking brake is engaged, buzzer stops and just warning lamp illuminates.

Key ON Cluster

Key ON Warning
buzzer
Relay

Engine overheat Parking switch

switch

EEN0002A
COOLING FAN CL-9

COOLING FAN
Removal and Installation

<D4AF, D4AE, D4AL>

10
5
8
7
6
4

9
1
21N·m(2.1kgf·m) 3
21N·m(2.1kgf·m)

<D4DA, D4DB> 10
5

7 8
6
4
2

9
1
21N·m 3
(2.1kgf·m) 21N·m(2.1kgf·m)

<Fixed Cooling Fan>

6
Disassembly sequence
2 1. Nut
10 2. Cooling fan
8 3. Nut
4. Auto cooling fan
5. V-belt
7
1 6. Bolt
21Nm (2.1kgf·m) 7. Coupling plate
8. Spacer
9. Water pump pulley
10. Water pump assembly

JCW25011/EDAC003A
CL-10 COOLING SYSTEM

Inspection of Autocool Fan Coupling

CAUTION
The autocool fan coupling is a non-maintainable assembly and
it must be replaced as an assembly if defective.

VTW25-001

1. While the engine is cold, move the entire fan coupling unit in
the axial direction. If there is an excessive play, the bearing is
defective requiring replacement.

VTW25-002

2. Rotate the fan blade tip with fingers. If fan idling is out of ser-
vice limit, replace the autocool fan coupling.

VTW25-003

3. If there is mud, dust, or dirt on the bimetal, clean with wire

brushes.
CAUTION
Do not apply excessive force to the bimetal during cleaning.

VTW25-004

INSPECTION AND ADJUSTMENT OF V-BELT

TENSION 12~16mm

1. Adjust the belt tension to obtain the specified belt deflection

when the center of each belt is pressed with a force of approxi-
mately 98N (10 kgf).

Specified belt deflection Result

CW25-016

12~16mm Adjust
WATER PUMP CL-11

NOTE:
1. A slack belt can be a cause of overheating and under-
charge.
2. An excessively tight belt may result in damaged bear-
ings and belts.
3. All two velts must be replaced as a complete set.

2. Adjustment of Fan Belt

To adjust the fan belt tension, slightly back off the alternator
attaching nut and adjusting bolt and move the alternator. 82Nm
(8.4 kgf·m)

91Nm
(9.3 kgf·m) VTW25-005

D4AF2489

WATER PUMP <D4AL, D4AF, D4AE>

CAUTION
The water pump assembly is non-maintainable and must be
Water pump
replaced as an assembly if defects are evident.

D4AF0399

<D4DA, D4DB>

VTW25-006
CL-12 COOLING SYSTEM

THERMOSTAT
Removal and Installation

Fit the projected of

thermostat to the
3 1. Thermostat cover
recess of case
2. Thermostat
3. Thermostat case
5 4. Bypass pipe
5. Water temperature
gauge unit
4 Apply engine oil to
prevent damage

CW25-021

Inspection

Stirring rod

Thermometer
Wire
Valve opening temperature
NV 80 to 84°C

Container

Valve lift/temperature
NV 10 or more / 95°C

Heat source

NV ... Norminal Value

D4AF0416
WATER TEMPERATURE GAUGE UNIT, ENGINE OVERHEAT SWITCH CL-13

Agitate water in the container with the stirrer to obtain uniform

temperature. For the inspection, use the following procedures.
1. Slowly heat water to the thermostat valve opening temperature.
Keep this condition for about five minutes and make sure that
the valve is open.
2. Raise the water temperature up to 95°C.
Keep the condition for five minutes and measure the lift of pellet.
3. Lower temperature down to 65°C or below and ensure that the
valve is fully closed.
If the thermostat is found defective in any of the above items,
replace it with a new one.
NOTE:
Support the thermostat so that the heat will not directly
transfer to it.

WATER TEMPERATURE GAUGE UNIT, ENGINE OVERHEAT SWITCH

Cylinder head
Water temperatue gauge unit
34N·m(3.5kgf·m)

Engine overheat
switch

V-belt

Crankcase
EENG0001A
CL-14 COOLING SYSTEM

Inspection
1. Put the sensor in water and increase the water temperature to
measure the resistance.

ECLA012E

2. If the measurement radically deviates from specification,

replace. Terminal(A)
(Air heater control
3. Measure the resistance across terminal (A) and body for water element)
Terminal(B)
(Water temperature
temperature gauge element and across terminal (B) and body gauge element)
for air heater control element.

Temperature
(°C) -20°C 20°C 60°C 80°C 100°C
Terminal
+4.9
A - - - 51.9 -4.4 27.4 +1.9
-1.2
ECLA012F

B 24.8±2.5 3.25±0.33 -620 -300 -

RADIATOR CL-15

RADIATOR
Removal and Installation

11

8
3

10

<With intercooler>

1
2

Disassembly sequence
1. Rod
2. Plate
3. Intercooler
4. Revervoir tank hose
5. Revervoir tank
6. Revervoir tank bracket
7. Radiator upper hose
8. Radiator lower hose
9. Radiator shroud
10. Radiator
11. Radiator cap
CUBCL003
CL-16 COOLING SYSTEM

Inspection
1. Using a copper, wire or similar device, remove dirt, mud, and
bugs from the front of radiator core with care to prevent dam-
age to tubings.

D4AF0402

2. Connect a hose to one of the radiator ports, cap the other port,
and immerse the radiator into water. Using a radiator cap tester, Inspection pressure
135 kPa (1.4 kgf/cm²)
force the compressed air under the specified inspection pres-
sure from the hose end to check for leaks.
If there is a leak, resolder the point of leakage or replace the
radiator.

D4AF0409

3. Inspection of pressure cap

Apply the specified pressure to the pressure cap with the Pres- Specified pressure
81~108kPa
sure Cap Tester to check to see if the pressure valve opens to (0.83~1.1kgf/cm2)
discharge air. If the pressure valve fails to discharge air at the Pressure cap
tester
specified pressure, replace the pressure cap.

CW25-026

Washing with Cleaning Solution(When radiator clogging or

coolant contamination are serious)
1. Discharge coolant from the radiator, crankcase, and reservoir tank.
2. Ready a mixture of Genuine HMC Radiator Cleaner (5 to 10%)
and tap water.
Pour the specified amount of mixture into the radiator.

D4AF0427

3. Run the engine to raise the solution temperature to around 90°C.

Let the engine run at idle for another 30 minutes, then remove
the solution.

D4AF0428
GAS LEAKTEST CL-17

4. After discharging the solution, fill the system with tap water
(preferably hot water) and, with the water temperature kept at
around 90°C, run the engine at idle for about 10 minutes. Then,
drain water.
Continue flushing until the drained water runs clear.

D4AF0426

RESERVIOR TANK
Reservoir tank reserves the over flowing coolant from the radiator
and replenishs the radiator with coolant to maintain the radiator
always with enough coolant.

VCW25-007-1

GAS LEAK TEST

Bubbles
Air or exhaust gas leaked into the coolant prompts corrosion and
rust formation. Perform the following check and, if defects are found,
take remedial action.
1. Inspection
Remove the pressure cap from the radiator, and run the en-
gine to raise the coolant temperature up to around 90°C. D4AF0430

If bubbles continue forming in the coolant under the condition,

it indicates that air or exhaust gas has leaked into the coolant.

2. Causes
If air is trapped in coolant, check cylinder head bolts, water
pump mounting bolts, and hose connections for looseness.
Check also hoses for damage.
If the exhaust gas has leaked into coolant, check the cylinder
head gasket or nozzle tube end stake for damage. Check also
cylinder head for cracks.

BLEEDING THE COOLING SYSTEM

1. With the pressure cap removed from the radiator, let the en-
gine run at idle with coolant temperature of about 90°C to bleed
the system completely. (If the system is provided with a heater,
place the heater lever in the maximum-temperature position to
allow coolant to circulate through the heating system.)
2. After the system has been bled of air, add coolant to radiator
and reservoir tank as required.