Group 14

Cooling

Pub No. TWME9502-14

 14

GROUP 14 COOLING

SPECIFICATIONS .................................................................................. 2

STRUCTURE AND OPERATION ........................................................... 2

TROUBLESHOOTING ............................................................................ 6

INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

• Replacing Coolant and Cleaning Cooling System .......................................... 8
• Air Bleeding of Cooling System ...................................................................... 10
• Gas Leakage Test ............................................................................................. 10

RADIATOR AND FAN SHROUD .......................................................... 12

SURGE TANK ....................................................................................... 16

COOLING FAN AND V-BELT ............................................................... 18

WATER PUMP ...................................................................................... 21

THERMOSTAT ...................................................................................... 22

14-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Kind of cooling system Forced water circulation system
Water pump type Belt-driven involute type
Thermostat type Wax-pellet, bottom bypass type (with jiggling valve)
Automatic cooling fan coupling type Continuous control type
Radiator type Tube and corrugated fin type
Coolant capacity L {qts} 21 {22}

STRUCTURE AND OPERATION

Cooling System (Flow of Coolant)
1 Pressure cap
2 Surge tank
3 Suction pipe
2 4 Air pipe
1
5 Thermostat
3 4 6 Water pump
5
7 Radiator
8 Cooling fan
9 Oil cooler
10 Water inlet pipe
11 11 Water level sensor
10
6

9
7

11693

Surge tank 2 is installed at a higher position than radiator 7 and automatically adds coolant when the coolant level in the
radiator drops.

14-2
 14
Water Pump
1 Case
2 Unit seal
3 Impeller
1 4 Ball bearing
5 Flange

A : Drain hole
2

3
5 4
A

08363

Thermostat
1 Thermostat cover
2 Thermostat
A 3 Thermostat case
B C
A : To radiator
B : When low coolant temperature
1 C : When high coolant temperature
2 D : From cylinder head
E : To water pump

3 Thermostat 2 is a bottom bypass type that uses wax pellets

D as its regulating element. As the wax changes its form from
solid to liquid according to changes in temperature, the
volume of the wax changes. Therefore, the position of the
E
06361 valve, changed by the coolant temperature, regulates the
flow of the coolant to the radiator and water pump (bypass
side) and controls the coolant temperature.

14-3
STRUCTURE AND OPERATION
Cooling System Electric Circuit
● Water temperature gauge circuit
1 Fuse box
2 Meter cluster
3 Water temperature gauge
4 Water temperature sensor

* : To cold start switch

11673

14-4
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● Water level sensor and overheating circuit
1 Fuse box
2 Meter cluster
3 Water level warning lamp
4 Parking brake switch
5 Water level control unit
6 Buzzer
(Buzzer does not work when the
parking brake is engaged.)
7 Water level sensor
8 Overheating switch

15069

When this circuit detects insufficient coolant or extremely high coolant temperature, it lights water level warning lamp 3
and sounds buzzer 6 to warn the driver of the abnormal conditions.

When water level sensor is activated

• 1→5→7→Ground
• Water level control unit 5 detects insufficient coolant.
→3
→

• 1→5→Ground
→

→6
• When the sensor is activated, water level warning
lamp 3 lights up and buzzer 6 sounds.

15070

When overheating switch is activated

• 1→3→8→Ground
→


→6
• When the switch is activated, water level warning
lamp 3 lights up and buzzer 6 sounds.

15071

14-5
TROUBLESHOOTING

Symptoms

Overheating (Low cooling effect)

Coolant loss excessive

Remarks

Noise occurs
Overcooling
Possible causes
Loose or damaged ● ●
V-belt Tension excessive ●
Oily ●
Water pump installation faulty ● ● ●
Unit bearing faulty ● ●
Water pump Impeller faulty ● ●
Unit seal faulty ● ●
Unit bearing-to-flange and to-impeller fitting loose ● ●
Case installation faulty ● ●
Valve opening temperature too high, valve remains closed ●
Thermostat Valve opening temperature too low, valve remains open ●
Gasket faulty ● ●
Water level sensor leaking water ● ●
Space between core and fin clogged ●
Radiator
Core cracked or soldered part separated ● ●
Pressure cap airtightness poor ●
Surge tank
Water level sensor leaking water ● ●
Cooling fan Fan shroud installation faulty ● ●
Bearing faulty ● ●

Automatic cooling Bimetal damaged ●

fan coupling Bimetal contaminated with foreign particles ● ●
Silicon oil leaking ● ●
Oil cooler mounted incorrectly ● ● Õ Gr 12
Oil cooler
Gasket faulty ● ● Õ Gr 12
Cylinder head mounted incorrectly ● ● Õ Gr 11
Cylinder head
Gasket faulty ● ● Õ Gr 11
Coolant quantity insufficient ●
Coolant passage furred and clogged ●
Water hose installation faulty ● ●
Exterior temperature extremely cold ●

14-6
 14

MEMO

14-7
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Replacing Coolant and Cleaning Cooling System
1 Pressure cap
2 Oil cooler drain plug
1 3 Crankcase drain plug
4 Radiator drain plug
2

4
11694

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
2 Oil cooler drain plug 34 to 39 {25 to 29, 3.5 to 4.0} —
3 Crankcase drain plug 98 {12, 10} —

Using the radiator for a long period of time without cleaning it will cause overheating because rust and scale deposits
will accumulate inside the cooling system. Periodical cleaning is recommended.
● Draining coolant
First loosen pressure cap 1, to lower the pressure in the cooling system, before draining coolant.
WARNING–
• You must make sure that the engine coolant is cold before draining it so as not to scald yourself.
• It is dangerous to open pressure cap 1, when the coolant temperature is high, without taking due care
because the hot water would spray out. Be sure to cover the pressure cap with a cloth and loosen slowly to
bleed the pressure before opening fully.

● Cleaning procedure
• Keep the coolant temperature at approximately 90°C {194°F} so that the thermostat valve remains open and the
coolant continues to circulate in the radiator.
• For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator with
corrugated cardboard or something similar.
• Set the temperature adjusting lever of the heater controller at maximum so that the coolant can circulate freely in the
heater piping area.
• In cases where a great amount of rust has accumulated it often happens that as a result of cleaning the radiator
starts leaking. Conduct a thorough check for leakage after cleaning.
• Soft water to be used should have the following properties.
CAUTION–
Do not use hard water as it causes scale and rust.

Required properties of soft water

Total hardness 300 ppm or less Total dissolved solids 500 ppm or less
Sulfate SO4– 100 ppm or less pH 6 to 8
–
Chloride Cl 100 ppm or less

14-8
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Method of cleaning the cooling system depends on its condition.

● Ordinary condition ● Extremely dirty coolant ● Clogged radiator

Cleaning using water Cleaning using Radipet 7 or equivalent

Drain the coolant

Make a solution of FUSO Radiator Cleaner (Radipet 7 or

equivalent) in a 5 to 10% ratio to the total volume of
coolant
(Work procedure)
Fill the radiator with the solution

Keep the solution temperature at 90°C {194°F} and let

the engine idle for 30 minutes
CAUTION–
Be sure to allow the engine to idle for 30
minutes only. Circulating the solution in the
system for more than an hour might cause
the system to breakdown

Drain the water and the

solution

Fill with soft water (boiled preferably)

Keep the water temperature at 90°C {194°F} and let the engine
idle for 10 minutes

Drain the water

If the drained water is clear, cleaning has

been successful. If it is still muddy, repeat the
procedure

DANGER–
If FUSO DIESEL LONG LIFE COOLANT solution gets in your eyes accidentally, you must immediately rinse
your eyes with copious amounts of water, and be sure to consult a doctor.

WARNING–
FUSO DIESEL LONG LIFE COOLANT is inflammable. Do not put it near naked lights.

NOTE
• After cleaning with solution, fill with coolant as quickly as possible.
• To prevent freezing of the coolant and corrosion of the cooling system, use specified coolant solution of FUSO
DIESEL LONG LIFE COOLANT. (See the Owner’s Handbook for use of these materials.)
14-9
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Air Bleeding of Cooling System
• Remove the pressure cap and keep the coolant temperature at 90°C
{194°F} while letting the engine idle and bleed the air out completely.
Keep the temperature adjusting lever of the heater controller at maxi-
mum so that the coolant can circulate freely in the heater piping area.
• After completing adequate air bleeding of the cooling system, refill
coolant sufficiently enough for the surge tank.

Gas Leakage Test

Air or exhaust gas in the coolant increases corrosion and rusting in the
1 system. Therefore, carry out the following test:
• Remove surge tank pressure cap 1 and check if the coolant level
comes up to the lip of the tank.
A • Put the end of overflow pipe A into water tank B.
WARNING–
Be sure that the coolant temperature is low enough so that hot
coolant does not spout out when you loosen pressure cap 1.
B
11676

• Run the engine to bring the coolant temperature to approximately

90°C {194°F}.
• Lift lever D of pressure cap 1.
• If air bubbles C continuously rise in water tank B, it is an indication that
D
air or exhaust gas has gotten into the coolant.
• If it is air, it is possible that the cylinder head bolts, the water pump
mounting bolts or the hose connections are loose, or that the hose is
B damaged.
• If it is exhaust gas, it is possible that the cylinder head gaskets are
C 11677 damaged, or that the cylinder head is cracked.

14-10
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MEMO

14-11
RADIATOR AND FAN SHROUD
● Removal sequence
1 Hose clamp
10 2 Outlet hose
Ê 1Ê 3 Hose clamp
3 4 Supply hose
Ê 5 Hose clamp
3 6 Inlet hose
7 Support rod
10 1Ê 8 Rubber sheet
5Ê 9 Radiator assembly
Õ P14-14
*1 10 Shroud seal
*3 11 Fan shroud
*2
*1 : Cooling fan
5Ê
*2 : Frame
8
*3 : Intercooler ^ Gr 15

7
● Installation sequence
Follow the removal sequence
11695
in reverse.

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
11, *1 Clearance between fan shroud and cooling fan tip 4.5 to 8.3 {0.18 to 0.33} — Adjust

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1, 3, 5 Hose clamp 3.9 {2.9, 0.4} —

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

11 Tip clearance spacer MC019470 Adjustment of clearance between fan

shroud and cooling fan
50 {1.97} 5 {0.20}

00189

14-12
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246
◆ Service procedure
Installation of hose
The depth of hose installation is as follows.
A : 35 mm {1.38 in.}
B : 40 mm {1.58 in.}
A
A
4
A
2

6
9

9
11696

Installation of radiator assembly

9
Tighten nuts until the thickness of rubber sheet 8 conforms to the
specified value.
13.3 mm *2 : Frame
{0.52 in.}
13.3 mm
{0.52 in.}

8
*2

G
11680

Installation of fan shroud

0 11
Adjust using 0 tip clearance spacer so that clearance A conforms to the
standard value all around the periphery.
*1 : Cooling fan
A

*1
11681

14-13
RADIATOR AND FAN SHROUD
Radiator Assembly
● Disassembly sequence
1 Radiator shroud
2 Drain cock
3 Radiator

● Assembly sequence
Follow the disassembly sequence in reverse.

11697

Service standards
Location Maintenance item Standard value Limit Remedy
3 Radiator air leakage (Air pressure of 150 kPa 0 cm3 {0 cu. in.} — Correct
{21 lbf/in2, 1.5 kg/cm2}) or replace

A
B
3
◆ Service procedure
Inspection of radiator
• Install radiator cap tester B by connecting hose A to the upper tank,
C
and insert plug C.
• Plug lower tank opening with plug C, and immerse the radiator in a
water tank.
• Apply specified air pressure of 150 kPa {21 lbf/in2, 1.5 kg/cm2} using
cap tester B, and check if there is any air leakage.
3
• If you find air leakage, correct or replace radiator 3.
C
00197

14-14
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MEMO

14-15
SURGE TANK
● Disassembly sequence
Ê 1 Clamp
10 8 2 Air hose
3 Clamp
4 Water hose
1 5 Clamp
6 Supply hose
Ù9 7 Pressure cap
8 Surge tank
5Ê 9 O-ring
10 Water level sensor ^ Gr 54

3 *1 : Water inlet pipe

*2 : Air and water suction pipe
Ê5 Ù : Non-reusable parts
*1

● Assembly sequence
1 Follow the disassembly sequence in reverse.
3

*2

11396

Service standards
Location Maintenance item Standard value Limit Remedy
7 Pressure cap valve opening pressure 69±15 kPa — Replace
{10±2.1 lbf/in2, 0.7±0.15 kgf/cm2}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
5 Clamp 3.9 {2.9, 0.4} —
10 Water level sensor 2.9 to 3.9 {2.2 to 2.9, 0.3 to 0.4} —

14-16
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A
246
◆ Service procedure
Installation of hose
The depth of hose installation is as follows.
A : 15 mm {0.59 in.}
2
8 B : 30 mm {1.18 in.}
4
A
B 6
*1

7
*2 B 11398

Inspection of pressure cap

(1) Pressure valve opening pressure

If the measured value deviates from the standard value, replace
pressure cap 7.

7 00194

8 (2) Inspection of vent valve

• Check that the coolant level comes up to the lip of surge tank 8. If
7
the level is low, add coolant.
• Tighten pressure cap 7.
A • Put the end of overflow hose A into water tank B.
• Check coolant level C of water tank B.
• Run the engine at a high revolution to increase the coolant tem-
perature.
C
• Stop the engine when some of the coolant in surge tank 8 has
B
11504 overflown into water tank B.
• Leave things for a while.
• Check the time it takes for the coolant temperature to return to the
ambient temperature, and check whether coolant level C in the tank
is the same as before running the engine.
• If the coolant level has not returned to that before running engine,
replace pressure cap 7.

NOTE
Do not remove pressure cap 7 before the coolant temperature
decreases to the ambient temperature. If you do the coolant
will not return to reservoir tank A because negative pressure in
the radiator is lost.

14-17
COOLING FAN AND V-BELT
● Removal sequence
1 V-belt (Air-conditioner)
2 V-belt (Fan)
*1 3 Nut
4 Bolt
5 Fan spacer
6 Cooling fan
7 Automatic cooling fan coupling
4 8 Torsional damper
6
*1 : Cooler compressor
*2 *2 : Tension pulley

● Installation sequence
Follow the removal sequence in reverse.
8
5
3

11515

CAUTION–
• Be sure to replace automatic cooling fan coupling 7 as an assembly if it is faulty because it is a unit
construction.
• Be sure to replace V-belts 2 as a set to maintain even tension between them.

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
1 V-belt tension (Air-conditioner) 16 to 20 {0.63 to 0.79} — Adjust
2 V-belt tension (Fan) 12 to 16 {0.47 to 0.63} — Adjust

0 Special tools
Location Tool name and shape Part No. Application

1, 2 Belt tension gauge MH062345 Measurement of tension of V-belt

03612

14-18
 14

12
◆ Service procedure

[Inspection]
V-belt

D
Measure the extent of flex A when the center of V-belts 1, 2 as illustrated
C is depressed with a force of approximately 98 N {72 lbf, 10 kgf}.
B : Alternator pulley
A C : Water pump pulley
D : Cooler compressor pulley (Air-conditioner)
B A E : Tension pulley
F : Crankshaft pulley
E

F 11518

● Use of special tool belt tension gauge

G
• Set upper O-ring G of 0 belt tension gauge to 98 N {72 lbf, 10 kgf}
(push load) on graduation H.
H • Set lower O-ring J of 0 belt tension gauge to graduation K (maxi-
0 mum flex of belt).

K 03613

• Place 0 belt tension gauge at the center of V-belts 1, 2 perpen-

dicularly as illustrated and push top L all the way down until upper
L G
O-ring G hits upper edge M.
M
1, 2

03614

• Measure the extent of flex A of V-belts 1, 2 at this point, and if the

A measured value deviates from the standard value, adjust as fol-
lows.

1, 2

03615

14-19
COOLING FAN AND V-BELT
[Adjustment]
P (1) Adjustment of V-belt tension for fan
• Loosen alternator mounting bolts N (two places), and adjust the
tension of V-belts 2 using adjusting bolt P.
• After adjustment, tighten the bolts and nuts securely.

CAUTION–
• Bear in mind that excessive tension of V-belts 2 might damage
N 2 the belts and bearings that engage with the V-belts.
11519
• Be sure to replace V-belts 2 as a set to maintain even tension
between them.
• Be careful not to let oil stick to V-belts 2, if oil gets onto the
belts, it causes slipping, resulting in overheating and insuffi-
cient battery charging.

(2) Adjustment V-belt tension for air-conditioner

• Loosen tension pulley mounting nut Q, and adjust the tension of
R V-belt 1 using adjusting bolt R.
• After adjustment, tighten the bolt R and nut Q securely.
CAUTION–
• Bear in mind that excessive tension of V-belt 1 might damage
Q the belt and bearings that engage with the V-belt.
• Be careful not to let oil stick to V-belt 1, if oil gets onto the belt,
it causes slipping, resulting in poor performance of the air
1 11520
conditioner.

7 Automatic cooling fan coupling

[Inspection]
Carry out the following inspection of automatic cooling fan coupling 7 and
if any fault is found, replace the unit.
• Check for any leakage of lubricating oil sealed in the coupling body.
• Rotate automatic cooling fan coupling 7 by hand, and check for any
7 irregularity in rotation related to the coupling bearing or any abnormal
noise.
• Check for any excessive play of automatic cooling fan coupling 7 in
11516
the axial direction when the engine is cool.

[Cleaning]
• If there are any foreign particles sticking to bimetal A, remove them by
brushing lightly.

7 11517

14-20
WATER PUMP 14
● Removal sequence
2 1 Water pump pulley
2 Upper shroud stay
3 Water pump
4 O-ring

Ù : Non-reusable parts

● Installation sequence
Follow the removal sequence in reverse.

4
-
3
Ù
1
11698

CAUTION–
• Be sure to replace water pump 3 as an assembly if it is faulty because it is a unit construction.
• Never apply engine oil to the O-ring because it will cause the O-ring to swell.

- Lubricant
Location Points of application Kinds Quantity
4 Periphery of O-ring Soapy water As required

14-21
THERMOSTAT
● Disassembly sequence
2
1 Eye bolt
2 Air and water suction pipe
3 Water inlet pipe
4 Thermostat cover
1Ê
3 5 Thermostat cover gasket
6 Thermostat
7 Thermostat case
8 Thermostat case gasket
9 Bypass pipe
4 10 O-ring
11 Water temperature sensor
(Water temperature gauge and multi-
Ù purpose timing control unit)
^ Gr 54
8Ù 12 Overheating switch ^ Gr 54
13 Water temperature sensor
(Pre-stroke control type injection pump)
7 ^ Gr 54
Ê 11
Ù : Non-reusable parts

Ê 12
● Assembly sequence
Follow the disassembly sequence in re-
10 verse.
-
Ù CAUTION–
Never apply engine oil to O-ring 10 be-
9 13 cause it will cause the O-ring to swell.
Ê
Ê1
11374

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
6 Thermostat Valve opening temperature 82±2°C {180±3.6°F} — Replace
Extent of valve lift (95°C {203°F}) 10 {0.39} or more — Replace

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Eye bolt 25 {19, 2.6} —
11 Water temperature sensor 34±6.9 {25±5.1, 3.5±0.7} —
12 Overheating switch 27 to 41 {20 to 30, 2.8 to 4.2} —
13 Water temperature sensor 34±6.9 {25±5.1, 3.5±0.7} —

- Lubricant
Location Points of application Kinds Quantity
10 O-ring Soapy water As required

14-22
 14

5
A 5
◆ Service procedure
Mounting of thermostat cover gasket
Mount thermostat cover gasket 5 on thermostat case 7 in the direction as
illustrated.
6 A : Sealant application surface

11375

A
B 6
6 Thermostat
[Inspection]
C
Stir the water using stick A to maintain an even water temperature in the
E
container, then carry out the following tests. If the measured value
deviates from the standard value, replace thermostat 6.
(1) Valve opening temperature
• Hold thermostat 6 with wire E so as not to get the thermostat too
close to heat D.
• Heat the water gradually to raise the temperature to the valve
opening temperature.
F D
• Maintain this temperature for five minutes and make sure that valve
00218 B has opened.
• Make sure that valve B has closed when the water temperature has
dropped to 65°C {149°F}.
C : Water temperature gauge

(2) Extent of valve lift

Measure valve lift F, while maintaining the water temperature a little
higher than the valve opening temperature, with valve B fully open for
five minutes.

14-23