Coolant inspection (RZ4E-TC)

1. Coolant safety information

Warning
Inspection, refilling, and replacement should be performed when the engine has cooled sufficiently.
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap or reserve tank cap, place a thick cloth over the cap after the coolant
has cooled, and turn it slowly to release the pressure before removing it.
Do not drink the coolant as it is poisonous.
If accidentally swallowed, immediately induce vomiting and seek the advice of a doctor.
If coolant has gotten in your eyes, immediately flush it out with running water for 15 minutes or more.
Seek the advice of a doctor if there is any irritation, etc.

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If any coolant has gotten on your skin, wash it away with large amounts of water and soap.
Seek the advice of a doctor if there are any complications.
When storing, seal tightly and keep in a location out of reach of children.
Keep coolant away from flames as it is flammable.

Caution
In order to prevent damage to the engine due to freezing of the coolant as well as to protect the
cooling system from corrosion, mix the specified coolant and water to a concentration of 50% each.
Rustproof ability declines with a coolant concentration of 30% or less.
Overheat possibility arises with a coolant concentration of 60% or more.
If coolant with a concentration other than that specified is used, anti-freezing performance may
decrease, causing freezing to occur.
Do not use a coolant other than genuine Isuzu coolant.
If the vehicle or engine is used in a cold area at -30°C {-22°F}, use an engine coolant with 55%
concentration.

2. Coolant inspection

1. Engine coolant level inspection

1) Inspect the engine coolant level in the radiator reserve tank, and verify that it is between the MAX line and the
MIN line.

2) Open the radiator cap and verify that the engine coolant is added to the filler section in the radiator.

Caution
Inspect the engine coolant level when the engine is cold.

3) When the engine coolant level is low, remove the reserve tank cap and add engine coolant to near the MAX
line.
Legend

1. Radiator reserve tank

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2. MAX line
3. MIN line

2. Coolant concentration inspection (Hydrometry method)

1) Measure the specific gravity and coolant temperature using a hydrometer to obtain the concentration from the
table.

Caution
Measure the temperature of the engine coolant within the range of 0°C {32°F} to 50°C {122°F}.
Use a container that has a depth greater than the length of the hydrometer.

Legend

1. Radiator
2. Hydrometer
 3. Coolant concentration inspection (Coolant scope method)

1) Measure the concentration using a coolant scope.

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3. Radiator cap inspection

1. Visual inspection

1) Inspect the radiator cap for the following.

Excessive wear
Damage

Note
Adjust, repair, or replace the radiator cap if any abnormal conditions are found.

2. Radiator cap opening valve pressure measurement

1) Measure the valve opening pressure of the pressurizing valve using the special tool.

Standard: 93.3 to 122.7 kPa { 1.0 to 1.3 kgf/cm2 / 13.5 to 17.8 psi }

Note
If the measured value is outside the standard range, replace the radiator cap.

SST: 5-8840-0277-0 - radiator cap tester

 SST: 5-8840-2603-0 - adapter

2) Inspect the vacuum valve located in the center of the valve seat side of the radiator cap for abnormal
conditions.

Note
If there is rust or fouling, or the valve seat cannot be moved by hand, clean or replace the radiator
cap.

3) Measure the radiator cap open valve pressure using the special tool.

Standard: -1.96 to 4.91 kPa { -0.0 to 0.1 kgf/cm2 / -0.3 to 0.7 psi }

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4. Coolant vehicle inspection

1) Inspect for engine coolant leakage from the following parts using a radiator cap tester.

Radiator
Water pump
Radiator upper hose
Radiator lower hose
Water pipe
Water rubber hose
Radiator reserve tank

196 kPa { 2.0 kgf/cm2 / 28 psi } Specified pressure

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Coolant replacement (RZ4E-TC)

1. Coolant drain

1. Engine coolant replacement period

160,000 km {96,000 miles} or 8 years (1st time)

80,000 km {48,000 miles} or 4 years (2nd time and thereafter)

Caution
Clean the radiator cap, radiator, and coolant passages at the same time.
If engine coolant is not replaced periodically, rust is generated due to engine coolant deterioration
may cause engine coolant leakage or radiator clogging, etc.
Do not use only water.

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To prevent damage to the engine, make sure to use the specified pre-diluted coolant.

2. Engine coolant drain

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
Legend

1. Drain plug

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4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

3. Engine coolant passage cleaning

1) Replenish the radiator with tap water.

Note
Fill with tap water to the brim of the radiator cap inlet.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with tap water.

Note
Fill with tap water up to the brim of the radiator cap inlet with the amount the water lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Install the radiator cap to the radiator.

4) Add tap water up to the MAX line of the radiator reserve tank.
Legend

1. Radiator reserve tank

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2. MAX line
3. MIN line

5) Start and idle the engine for 20 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when the tap water is hot, as doing so may result
in burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the tap water has cooled and
slowly turn to release pressure.

8) Loosen the radiator drain plug, and drain the tap water into a pan.

9) Loosen the drain plug on the cylinder block and drain the tap water into a pan.
 Legend

1. Drain plug

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10) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

11) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

12) Tighten the radiator drain plug.

2. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend

1. Radiator reserve tank

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2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
 Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

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Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
Auto tensioner removal (RZ4E-TC)

1. Cooling fan belt removal

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt removal".

2. Auto tensioner removal

1) Remove the idle pulley from the generator bracket.

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Legend

1. Idle pulley

2) Remove the auto tensioner from generator bracket.

Legend

1. Auto tensioner
2. Generator bracket

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Auto tensioner inspection (RZ4E-TC)

1. Auto tensioner inspection

1) Inspect the following parts for deformation or other abnormal conditions.

Note
Replace as a set if an abnormal condition is found in any of the parts.

Bolt
Spacer
Dust cover

2) Inspect the following parts for deformation or other abnormal conditions.

Note

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Replace the idle pulley as a set if an abnormal condition is found.

Pulley and bearing

Shaft

Legend

1. Bolt
2. Spacer
3. Dust cover
4. Pulley and bearing
5. Shaft

3) Inspect the auto tensioner for the following.

Wear
Damage

Note
Replace the auto tensioner if an abnormal condition is found.

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Auto tensioner installation (RZ4E-TC)

1. Auto tensioner installation

1) Install the auto tensioner to the generator bracket.

Tightening torque: 110 N・m { 11.2 kgf・m / 81 lb・ft }

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Legend

1. Auto tensioner
2. Generator bracket

2) Install the idle pulley to the generator bracket.

Tightening torque: 110 N・m { 11.2 kgf・m / 81 lb・ft }

 Legend

1. Idle pulley

2. Cooling fan belt installation

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".

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Cooling fan belt removal (RZ4E-TC)

1. Component views

Cooling fan belt

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Part name

1. Fan pulley
2. Cooling fan belt
3. Power steering oil pump pulley
4. Generator
5. Bolt
6. Bolt
7. A/C compressor
8. Crankshaft pulley
9. Auto tensioner pulley
10. Idle pulley

Tightening torque

5: 110 N・m { 11.2 kgf・m / 81 lb・ft }

6: 110 N・m { 11.2 kgf・m / 81 lb・ft }

2. Preliminary and post procedures

 1. Preliminary procedures

1) Open the engine hood.

2) Raise the vehicle.

3. Cooling fan belt removal

1) Set the torque wrench on the boss section of the auto tensioner.

2) Remove the cooling fan belt from the following parts by moving the auto tensioner pulley in the direction shown
in the diagram.

Water pump pulley

Generator
Auto tensioner pulley
Idle pulley
A/C compressor
Crankshaft pulley
Power steering oil pump pulley

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Legend

1. Boss section
Cooling fan belt inspection (RZ4E-TC)

1. Cooling fan belt inspection

1) Inspect the cooling fan belt for the following.

Wear
Damage

Note
If an abnormal condition is found, replace the cooling fan belt.

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Cooling fan belt installation (RZ4E-TC)

1. Component views

Cooling fan belt

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Part name

1. Fan pulley
2. Cooling fan belt
3. Power steering oil pump pulley
4. Generator
5. Bolt
6. Bolt
7. A/C compressor
8. Crankshaft pulley
9. Auto tensioner pulley
10. Idle pulley

Tightening torque

5: 110 N・m { 11.2 kgf・m / 81 lb・ft }

6: 110 N・m { 11.2 kgf・m / 81 lb・ft }

2. Cooling fan belt installation

 1) Set the torque wrench on the boss section of the auto tensioner.

2) Install the cooling fan belt to the following parts by moving the auto tensioner pulley in the direction shown in
the diagram.

Water pump pulley

Generator
Auto tensioner pulley
Idle pulley
A/C compressor
Crankshaft pulley
Power steering oil pump pulley

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Legend

1. Boss section

3. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Close the engine hood.

Cooling fan clutch removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3) Raise the vehicle.

2. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

3. Coolant drain

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.
 3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

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Legend

1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

4. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the blow-by hose from the air cleaner duct.

 3) Disconnect the air cleaner duct from the air cleaner and turbocharger.

4) Remove the air cleaner from the vehicle.

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Legend

1. Air cleaner
2. MAF and IAT sensor
3. Blow-by hose
4. Air cleaner duct

5. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the upper fan guide.

6. Radiator upper hose removal

1) Remove the radiator upper hose from the water outlet pipe and radiator.
 Legend

1. Radiator upper hose

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7. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

1. Fan guide
2. Clip
3. Fan shroud

8. Cooling fan belt removal

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt removal".

9. Cooling fan removal

 1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

10. Cooling fan clutch removal

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1) Remove the cooling fan clutch from the cooling fan.
Cooling fan clutch inspection (RZ4E-TC)

1. Cooling fan clutch vehicle inspection

1) Turn the cooling fan clutch by hand and inspect for interference.

2) Start and warm-up the engine until the fan clutch temperature becomes the standard value.

Standard: about 85 ℃ { about 185 °F }

3) Stop the engine.

4) Turn the cooling fan clutch by hand and check for considerable clutch torque.

Caution

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If it rotates easily, there is a silicon grease leakage so the cooling fan clutch should be replaced.

2. Cooling fan clutch inspection

1. Visual inspection

1) Inspect the cooling fan clutch for the following.

Wear
Damage

Note
If an abnormal condition is found, replace the cooling fan clutch.

2. Unit inspection

1) Warm until the fan clutch temperature becomes the standard value using a heat gun.
 Standard: about 85 ℃ { about 185 °F }

2) Turn the cooling fan clutch by hand and check for considerable clutch torque.

Caution
If it rotates easily, there is a silicon grease leakage so the cooling fan clutch should be replaced.

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Cooling fan clutch installation (RZ4E-TC)

1. Cooling fan clutch installation

1) Install the cooling fan clutch to the cooling fan.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2. Cooling fan installation

1) Install the cooling fan clutch and cooling fan as a set to the water pump.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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3. Cooling fan belt installation

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".

4. Fan guide installation

1) Install the fan guide to the radiator.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

 Legend

1. Fan guide

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2. Clip
3. Fan shroud

5. Radiator upper hose installation

1) Install the radiator upper hose to the water outlet pipe and radiator.

Legend

1. Radiator upper hose

6. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note
Wash with clean water, and drain the water.
 2) Install the radiator reserve tank to the upper fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

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3) Connect the radiator reserve tank hose to the radiator.

7. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

1. Air cleaner
2. MAF and IAT sensor
3. Blow-by hose
4. Air cleaner duct

2) Referring to the diagram, align the alignment mark positions and connect the air cleaner duct to the air cleaner
and turbocharger.
 Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in }

Legend

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1. Alignment mark

3) Connect the blow-by hose to the air cleaner duct.

4) Connect the connector to the MAF and IAT sensor.

8. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

9. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

10. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

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Legend

1. Radiator reserve tank

2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

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14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
Radiator removal (RZ4E-TC)

1. Component views

Radiator

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Part name

1. Radiator upper hose

2. Fan guide
3. Radiator
4. Radiator reserve tank hose
5. Drain plug
6. Radiator reserve tank
7. Bolt
8. Bolt
9. Fan shroud
 10. Radiator lower hose

Tightening torque

7: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

8: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery

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negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3) Raise the vehicle.

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Coolant drain

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.
 3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

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Legend

1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the blow-by hose from the air cleaner duct.

 3) Disconnect the air cleaner duct from the air cleaner and turbocharger.

4) Remove the air cleaner from the vehicle.

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Legend

1. Air cleaner
2. MAF and IAT sensor
3. Blow-by hose
4. Air cleaner duct

6. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the upper fan guide.

7. Radiator upper hose removal

1) Remove the radiator upper hose from the water outlet pipe and radiator.
 Legend

1. Radiator upper hose

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8. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

1. Fan guide
2. Clip
3. Fan shroud

9. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.
10. Radiator lower hose disconnect

1) Disconnect the radiator lower hose from the water intake pipe.

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Legend

1. Radiator lower hose

11. Radiator removal

1. Manual transmission models

1) Remove the bracket from the radiator.

2) Remove the radiator from vehicle.

Caution
Do not damage the radiator core with the fan blade.
 2. Automatic transmission models

1) Disconnect the ATF hose from the radiator.

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2) Remove the bracket from the radiator.

3) Remove the radiator from vehicle.

Caution
Do not damage the radiator core with the fan blade.
Radiator inspection (RZ4E-TC)

1. Radiator inspection

1) Inspect the radiator fin for the following.

Deformation
Collapsing

Note
Repair the radiator fins if deformation or collapsing is found.

Caution
If repairing, do not damage the base of the fins.

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2. Radiator cleaning

1) Clean the radiator interior and coolant passages using tap water.

Note
Wet the front and back surfaces of the radiator sufficiently.
Wipe away any rust or water deposits.

Caution
Do not apply high pressure washing to the radiator, intercooler, or peripheral parts while they are
installed on the vehicle.

2) Seal the radiator hose connection using a cap, cloth tape, etc.

3) Clean any light dirt with tap water.

Caution
At this time, do not use a high-pressure washing machine or brush.

4) Apply a neutral detergent that contains approximately 8% surface acting agent to the front and rear surfaces of
the radiator fin, and leave for 10 minutes.

Caution
Do not use other materials than mild detergent, because using other materials may cause corrosion.

5) Clean the radiator using a high-pressure washing machine.

Note
When dirt is not washed off sufficiently, repeat the cleaning.

Caution
High-pressure water should be applied perpendicularly to the fins from the engine side of the
radiator.
High-pressure water should not be taken too close to the fins, or cause them to become deformed.
Legend

1. Radiator

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6) Make sure any dirt on the radiator fins has been completely washed off.

Note
If dirt remains, fine black particles can be seen adhering to the radiator fins.
When dirt is not washed off sufficiently, repeat the cleaning.

7) Clean the radiator using tap water.

Caution
Thoroughly rinse off all detergent from the core and plastic sections.

8) Remove the cap, cloth tape, etc., from the radiator.

9) Clean the radiator hose connections using tap water.

Caution
Thoroughly dry the hose connection after work.
Radiator installation (RZ4E-TC)

1. Component views

Radiator

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Part name

1. Radiator upper hose

2. Fan guide
3. Radiator
4. Radiator reserve tank hose
5. Drain plug
6. Radiator reserve tank
7. Bolt
8. Bolt
9. Fan shroud
 10. Radiator lower hose

Tightening torque

7: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

8: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2. Radiator installation

1. Manual transmission models

1) Install the radiator to vehicle.

Caution
Do not damage the radiator core with the fan blade.

2) Secure the radiator using the bracket.

Note
Support the radiator upper tank with the bracket.

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2. Automatic transmission models

1) Install the radiator to vehicle.

Caution
Do not damage the radiator core with the fan blade.

2) Secure the radiator using the bracket.

Note
Support the radiator upper tank with the bracket.

3) Connect the ATF hose to the radiator.

3. Radiator lower hose connect

1) Connect the radiator lower hose to the water intake pipe.

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Legend

1. Radiator lower hose

4. Cooling fan installation

1) Install the cooling fan clutch and cooling fan as a set to the water pump.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5. Fan guide installation

1) Install the fan guide to the radiator.

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Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

Legend

1. Fan guide
2. Clip
3. Fan shroud

6. Radiator upper hose installation

1) Install the radiator upper hose to the water outlet pipe and radiator.
 Legend

1. Radiator upper hose

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7. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note
Wash with clean water, and drain the water.

2) Install the radiator reserve tank to the upper fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

3) Connect the radiator reserve tank hose to the radiator.

8. Air cleaner installation

1) Install the air cleaner to the vehicle.

 Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

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1. Air cleaner
2. MAF and IAT sensor
3. Blow-by hose
4. Air cleaner duct

2) Referring to the diagram, align the alignment mark positions and connect the air cleaner duct to the air cleaner
and turbocharger.

Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in }

Legend

1. Alignment mark

3) Connect the blow-by hose to the air cleaner duct.

4) Connect the connector to the MAF and IAT sensor.

9. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

10. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

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11. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend

1. Radiator reserve tank

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2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
 Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

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Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
Radiator reserve tank removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2. Radiator reserve tank removal

Caution
Confirm that the engine has cooled sufficiently.

1) Drain engine coolant from the radiator reserve tank.

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2) Disconnect the radiator reserve tank hose from the radiator reserve tank.

3) Remove the radiator reserve tank from the fan guide.

Radiator reserve tank installation (RZ4E-TC)

1. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note
Wash with clean water, and drain the water.

2) Install the radiator reserve tank to the fan guide.

Tightening torque: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

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3) Connect the radiator reserve tank hose to the radiator.

2. Preliminary and post procedures

1. Post procedures

1) Close the engine hood.

Thermostat removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3) Raise the vehicle.

2. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

3. Coolant drain

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

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Legend

1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

4. Engine cover removal

1) Remove the engine cover from the engine.

Legend

1. Engine cover

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5. Radiator upper hose removal

1) Remove the radiator upper hose from the water outlet pipe and radiator.

Legend

1. Radiator upper hose

6. Thermostat removal

1) Disconnect the water hose from the water outlet pipe.

2) Remove the water outlet pipe from the thermostat housing.

3) Remove the thermostat from the thermostat housing.

Caution
 Do not damage the thermostat.

Legend

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1. Thermostat
2. Jiggle valve
Thermostat inspection (RZ4E-TC)

1. Thermostat inspection

1) Place the thermostat in water and gradually raise the water temperature to inspect the following items.

Temperature when beginning to open

Temperature when fully open
Valve lift amount when fully opened

Note
Place a plate on the bottom of the container so that the thermostat is not directly heated, or lift it up.
Make sure that the warm water is continually stirred so that a temperature differential does not occur.

Thermostat open valve

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temperature
Temperature
when beginning 82 ℃ { 180 °F }
to open
Temperature
95 ℃ { 203 °F }
when fully open
Lift amount 10 mm { 0.39 in }

Legend

1. Piece of wood
2. Stir rod
Thermostat installation (RZ4E-TC)

1. Thermostat installation

1) Install the thermostat to the thermostat housing with the jiggle valve facing the right side of the vehicle.

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Legend

1. Thermostat
2. Jiggle valve

2) Install the water outlet pipe to the thermostat housing.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3) Connect the water hose to the water outlet pipe.

2. Radiator upper hose installation

1) Install the radiator upper hose to the water outlet pipe and radiator.
 Legend

1. Radiator upper hose

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3. Engine cover installation

1) Install the engine cover to the engine.

Legend

1. Engine cover

4. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

5. Preliminary and post procedures

1. Post procedures
 1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

6. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

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Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

1. Radiator reserve tank

2. MAX line
 3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

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Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note
 Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.

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Water pump removal (RZ4E-TC)

1. Component views

Water pump

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Part name

1. Cooling fan
2. Nut
3. Fan pulley
4. Bolt
5. Nut
6. Water pump

Tightening torque

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Cooling fan clutch removal

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan clutch removal".

3. Water pump removal

1) Remove the water pump from the front cover.

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Water pump inspection (RZ4E-TC)

1. Water pump inspection

1. Visual inspection

1) Inspect the water pump for the following.

Corrosion
Wear
Damage

2) Inspect the impeller for the following.

Corrosion
Wear

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Damage

2. Water leakage inspection

1) Inspect the seal unit for water leakage.

2) Inspect the bearing unit for significant looseness and abnormal noise.

3) Inspect for fan center end play.

Standard: 0.2 mm or less { 0.008 in or less }

Water pump installation (RZ4E-TC)

1. Component views

Water pump

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Part name

1. Cooling fan
2. Nut
3. Fan pulley
4. Bolt
5. Nut
6. Water pump

Tightening torque

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Water pump installation

1) Install the water pump to the front cover.

 Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3. Cooling fan clutch installation

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Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan clutch installation".
Supplementary Information (RZ4E-TC)

1. Component views

Water pump

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Part name

1. Cooling fan
2. Nut
3. Fan pulley
4. Bolt
5. Nut
6. Water pump

Tightening torque

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Cooling fan belt

 cardiagn.com
Part name

1. Fan pulley
2. Cooling fan belt
3. Power steering oil pump pulley
4. Generator
5. Bolt
6. Bolt
7. A/C compressor
8. Crankshaft pulley
9. Auto tensioner pulley
10. Idle pulley

Tightening torque

5: 110 N・m { 11.2 kgf・m / 81 lb・ft }

6: 110 N・m { 11.2 kgf・m / 81 lb・ft }

Radiator
 cardiagn.com
Part name

1. Radiator upper hose

2. Fan guide
3. Radiator
4. Radiator reserve tank hose
5. Drain plug
6. Radiator reserve tank
7. Bolt
8. Bolt
9. Fan shroud
10. Radiator lower hose

Tightening torque

7: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

8: 6.5 N・m { 0.7 kgf・m / 58 lb・in }