F300-HD_Engine-CO-Cooling_System-Part1
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DAIHATSU
F300
[HD-ENGINE]
COOLING SYSTEM
TROUBLE SHOOTING CO- 2 PRECAUTIONS CO- 2 CHECK & CHANGE OF ENGINE
COOLANT CO- 2 WATER PUMP CO- 4 THERMOSTAT CO- 7 RADIATOR CO- 9
CO- 1
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TROUBLE SHOOTING
Problem Possible cause
Remedies
Page
Engine overheats Poor quality coolant
Water pump drive belt loose or missing
Dirt. leaves or insects on radiator
Leaky hoses; water pump. the thermo- stat housing, radiator, heater, core plugs or head gasket
Thermostat faulty Ignition timing retarded Radiator hose plugged or deteriorated Water pump faulty Radiator plugged or cap faulty
Cylinder head or block cracked or plugged
Replenish coolant.
Adjust or replace belt.
Clean radiator.
Repair as necessary.
Check thermostat.
Set timing. Replace hose.
Replace water pump. Check radiator.
Repair as necessary.
PRECAUTIONS
As regards water to be used as cooling water, use soft water which does not contain salts of minerals, cal
cium, magnesium and so forth.
0 If the coolant gets to the vehicle body, immediately flush away the coolant using water. 0 Never open the radiator cap when the cooling water is still hot. 0 The inside of the radiator is under a pressurized conditon when the cooling water is hot. Therefore, if the
radiator cap should be removed, the cooling water will blow off, possibly causing injuries such as scald.
CHECK & CHANGE OF ENGINE COOLANT
1. Check of coolant level
Check to see if the coolant level is between the LOW and
FU LL lines ofthe reserve tank.
If the coolant level is near the low level or below the low level,
add the coolant up to the full level.
2. Check of coolant quality
There should not be any excessive deposits of rust or water scales around the radiator cap or the radiator filler hole. Also,
the coolant should be free of oil. Change the coolant if it is excessively dirty. CAUTION:
Never open the radiator cap when the engine is still hot.
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Change of engine coolant (1) Remove the radiator cap. CAUTIDN: Never open the radiator cap and/or the drain plug when the engine is still hot. Care must be exercised to avoid getting scalded.
(2) Place an adequate container, below the radiator drain plug. Drain the coolant by removing the drain plug. (3) Close the drain plug. (4) Fill the system with water. (5) Start the engine, and stop it. (6) 'Repeat the steps (1) through (5) two to three times. NOTE: Replace the drain plug gasket with a new one.
(7) Fill the radiator and reserve tank with antifreeze solution in accordance with the instructions of the manufacturer of the antifreeze solution. CAUTION: Use a Good brand of ethylene-glycol base antifreeze solu- tion.
Coolant capacity (Vehicle with front heater):
5.5 liter (4.8 IMP qt) [excluding 1.0 liter (0.8 IMP qt) for reserve tank]
(8) Fill the system with water. (9) Start the engine. Check the coolant level. Add water, as
required.
(10) Tighten the radiator cap. (11) Warm the engine, until the radiator fan motor starts to
rotate. Afterwards, allow the coolant to cool down to nor- mal temperature. Recheck the coolant level at reserve tank. Add water to the full level, as required.
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WATER PUMP
COMPONENTS
Dust seal
Fluid coupling
W
*z Non reusable parts
REMOVAL OF WATER PUMP
1. Disconnect the battery ground cable from the negative (-)
terminal of the battery. Drain the coolant as follows. Open the radiator cap and drain plug, and allow the coolant to drain into a clean container. CAUTION: Never open the radiator cap and/or drain plug. When the en- gine is still hot.
2.
3. Remove the timing belt.
(See pages EM-21)
4. Remove the water pump by removing the attaching bolts and
nuts of the water pump.
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INSPECTION OF WATER PUMP-RELATED PARTS
1. Check the water pump pulley for damage or deformation.
Replace the water pump if it exhibits damage or deforma- tion.
2. Visually inspect the water pump rotor for damage or defor
mation. Replace the water pump if the water pump rotor exhibits damage or deformation.
3. Ensure that the water pump rotates smoothly by hand.
Replace the water pump if it will not rotate smoothly.
4. Check the water pump cover section of the cylinder block
for damage or wear. Replace the cylinder block if the water pump cover section exhibits damage or wear.
INSTALLATION OF WATER PUMP
1. Remove the gasket material from the water pump installing
surface of the cylinder block, using a gasket scraper.
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2. Remove the gasket material from the water pump, using a
gasket scraper.
3. Install a new gasket to the cylinder block.
4. Install the water pump tothe cylinder block. Tighten the at
taching bolts evenly over two or three stages tothe specified torque.
Tightening Torque: 1.5 - 2.2 kg-m (10.8 - 15.9 ft-lb)
NOTE:
After tightening bolts, ensure that the water pump rotates smoothly by hand.
6. Fill coolant.
(See Dage CO-3.)
CO-6
W
1
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Drain the coolant (See page CO-3).
CAUTION:
coolant is still hot.
2. Remove the radiator hose No. 2 from the water inlet.
WARNING: Cover the alternator to prevent entering the cooling water into
3. Remove the thermostat by removing the water inlet.
INSPECTION OF THERMOSTAT
1. Ensure that the thermostat vaive is closed completely at
room temperature 20°C (68°F) and the spring has no play. Replace the thermostat if the valve is open or the spring has a play.
2. Check the rubber gromrnet of the thermostat for damage or
crack. Replace the thermostat if the rubber grommet exhibits
damage or crack.
CO-7
Never open the radiator cap and/or drain plug when the
thealternator. U I U if
Waste
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3. lmmerse the thermostat in water, and check the valve open
ing temperature by heating the water gradually.
Valve lift
General specifications I 76 - 80 (168.8 - 176)
ECE & EEC specifications | 82 - as (179.6 - 186.8)
Replace the thermostat if the valve operation fails to conform to the specifications.
INSTALLATION OF THERMOSTAT
1. Assemble the thermostat in such a way that the jiggle pin
comes exactly at the top of the engine. NOTE: The thermostat should be installed in such a way the jiggle pin may face upward. Failure to observe this caution may cause engine malfunction.
2. Install the water inlet.
Tightening Torque: 0.6 - 0.9 kg-m (4.3 - 6.5 ft-Ib)
3. Fill coolant.
(See page CO-3.) 4. Start the engine and check it for leakage.
Repair the leaky point if the leakage exists.
5.
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RADIATOR
CLEANING OF RADIATOR
Using water or steam cleaner, remove mud and dirt from the radiator core.
CAUTION: When using a high pressure type cleaner, be careful not to IE deform radiator core fins. Keep a distance of more than 40 - 50 cm (15.75 - 19.69 inch) between the radiator core and cleaner nozzle when the cleaner nozzle pressure is 30 - 50 kg/cm2 (427 - 711 psi). wmwm Also, the injection angle of pressurized water shold be right angles to the radiator.
INSPECTION OF RADIATOR
1 _ Check of radiator cap gag'
(1) Check the radiator cap by means of a radiator cap testef ` `
to seegf the relief valve opens at a pressure of 0.6 - 1.05 kg/cm (8.53 - 14.9 psi).
.- A
kg/cmz (8.53 - 14.9 psi). lf the radiator cap does not conform to the specification, I Q replace the radiator cap. CAUTION: Never open the radiator cap when the engine is still hot.
(2) Check the seal packing of the radiator cap for damage. Replace the radiator cap with a new one, if any damage exists.
(3) Lift the valve at the vacuum side with your fingers.
Ensure that the valve is functioning properly. Replace the radiator cap with a new one, if the valve fails I;
_ to function. H I Q7 I
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2. Drain the coolant as follows:
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(1) Remove the radiator cap. 3 cAuT|oN; I Never open the radiator cap and/or drain cap when the 1 / coolant still hot. I 1 %
WRS8-C4304()
3. Removal of radiator
2. Check of cooling system for leakage nf,
(1) Fill the radiator with coolant. Attach a radiator cap tester. (2) Warm up the engine. / ‘V '_' (3) Apply a pressure of 1.2 kg/cm2 (17 psi) to the cooling V system by means of a radiator tester.
_ ff),
nppry at plcaaulv ul 1.4 ng/ulll UI ptil) LU LHB UUUIIIIQ _ system by means of a radiator tester.
_ (ff) 5 #__ if the pressure drops, check the hoses, radiator, water V' 7/ f
pump and heater for evidence of leakage. ' U If no external leakage is found, check the heater core, (1 cylinder block, cylinder head, oil cooler and throttle body "--- Tl for evidence of leakage. Check the hoses for deterioration, cracks, bulge or wnwcoose damage. Replace the defective part(s) if necessany. (4) Remove the radiator cap tester from the radiator. CAUTION: Never remove the radiator cap tester when the coolant temperature is still high.
REMOVAL OF RADIATOR
1 I ru.. UI I UI1 K a 1. Disconnect the ground cable terminal from the negative (-) Q/ terminal of the battery. \ 1
WR88-C0041
(1) Remove the reserve tank. yi (2) Remove the radiator hose No. 1 and No. 3 at radiator .gil
1%
CO-10
