92Rocky-CO-Cooling_System-Part1
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COOLING SYSTEM
DESCRIPTION CO- 2 TROUBLE SHOOTING CO- 3 AUTIONS CO- 3
PRECAUTIONS CO- CHECK & CHANGE OF ENGINE
COOLANT CO- 3 WATER PUMP C0- 5 THERMOSTAT CO- 8 RADIATOR CO-10
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COOLING SYSTEM
DESCRIPTION
The cooling system is a Water cooled, forced-circulation type. The cooling system employs a bottom by-pass type in which the thermostat equipped with a by-pass valve is provided at the inlet side. The cooling system is composed ot the radiator, water pump, cooling tan, fluid coupling, Water jackets of cylinder head and cylinder block, water hoses and their connecting parts.
Water outlet
Heater core
Rear heater core
Radiator hose Air breather hose
ng fan
J Radiétor reserve
tank
num coupling
Water imet Radiator outlet hose
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CQOLING SYSTEM
TROUBLE SHOOTING
Problem Possible cause
Remedies
Page
Poor quality coolant Water pump drive belt loose or missing
Dirt, leaves or insects on radiator
Leaky hoses, water pump, thermostat 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 piugged
Engine overheats
Change 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,
calcium, magnesium and so forth.
lf the coolant gets to the vehicle body, immediately flush away the coolant using water. Never open the radiator cap when the cooling vvater is hot.
cHEcK & cHANe.E oF ENG|NE »
Check to see if the coolant level is between the LOW and
FULL lines ofthe reserve tank.
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X Reserve coo|_AN'r l _W mcap 1. Check of coolant level
Check to see if the coolant level is between the LOW and f -" / FULL lines ofthe reserve tank. l lf the coolant level ls near the low level or below the low 1 //f * /L
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 or the time due
to change the coolant has already arrived.
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Wauso-cooos
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COOLING SYSTEM
3. Change of engine coolant
(1) Remove the radiator cap.
(2) Remove the engine undercover. (3) Place an adequate container below the radiator drain plug. Drain the coolant by removing the drain plug. (4) Close the drain plug. (5) Fill the system with Water. (6) Start the engine, and stop it. (7) Repeat the steps (1) through (5) two to three times. NOTE: Replace the drain plug gasket with a new one.
(8) Fitl the radiator and reserve tank with antifreeze solution in accordance with the instructions of the manufacturer ofthe antifreeze solution. CAUTION: Use a Good brand of ethylene-glycol base antifreeze solu- tion.
Coolant capacity (Vehicle with front heater):
5.5 liter (5.8 US qt) [excluding 1.0 liter (1.1 US qt) for reserve tank]
(9) Fill the system with Water. (10) Start the engine. Check the coolant level. Add water, as
required. (11) Tighten the radiator cap. (12) Warm the engine. Afterwards, allow the coolant to cool olovvn to the atmospheric temperature. Flecneck the coolant level at the reserve tank. Add coolant to the full level, as required. If no coolant remains at all in the reserve tank, recheck the coolant level in the radiator. Replenish the radiator with water, as required. Replenish the reserve tank with coolant up to the full level. NOTE: Here, the coolant refers to the mixture of water and an- tifreeze that has been mixed in accordance with the instruc- tions ofthe antifreeze manufacturer.
(13) Install the engine under cover with attaching bolts.
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COOLING SYSTEM
WATER PUMP
COMPONENTS
Dust seal
Nut
Fluid coupling
Water pump
REMOVAL OF WATER PUMP
1. Disconnect the battery ground cable from the negative (-)
terminat ofthe battery. Remove the engine under cover. Drain the coolant. (See page CO-4.) Open the radiator cap and drain plug, and allow the coolant to drain into a clean container.
4.
Remove the timing belt. (See pages EM-21.)
5. Remove the water pump by removing the attaching bolts
and nuts of the water pump.
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COOLING SQISTEM
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 ofthe 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 ofthe cylinder block, using a gasket scraper.
O £75
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COOLING SYSTEM
2. Remove the gasket material from the water pump, using a
gasket scraper.
3. install a new gasket to the cylinder block. ,K
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lnstall the water pump to the cylinder block. Tighten the QQA attaching bolts and nuts evenly over two or three stages to IQ ig Q Ng:
smoothly by hand.
5. Install the timing belt.
(See oaoe EM-30.) W/
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COOLING SYSTEM
THERMOSTAT
2.
Disconnect the ground cable terminal from the negative (-) terminal of battery. Drain the coolant (See page CO-4.)
Remove the power steering vane pump assembly. (See page EM-37.)
Remove the radiator hose No. 2 from the water inlet. CAUTION: Cover the alternator to prevent entering the cooling water to the alternator.
Remove the thermostat by removing the Water inlet.
INSPECTION OF THERMOSTAT
1
2
Ensure that the thermostat valve 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.
Check the rubber grommet of the thermostat for damage or crack. Replace the thermostat if the rubber grommet exhibits damage or crack.
REMOVAL OF THERMOSTAT
H
1. Disconnect the ground cable terminal from the negative (-)
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COOLING SYSTEM
3. lmmerse the thermostat in water, and check the valve open
ing temperature by heating the Water gradually.
Cold area _ Specifications | 82 - 86 (179.6 186.8)
Replace the thermostat if the valve operation tails to conform tothe 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 jiggie 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, 5.9 - 8.8 N-m)
3. Install the power steering vane pump assembly into posi
tion. (See page EM-77.)
4. Fill coolant.
5. Connect the battery ground cable to the negative (-) ter
minal of battery. 6. Start the engine and check it for leakage.
Repair the leaky point if the leakage exists.
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COOLING SYSTEM
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 deform radiator core fins. Keep a distance of more than 40 - 50 cm (16 - 20 inch) between the radiator core and cleaner nozzle when the cleaner nozzle pressure is 30 - 35 kg/cmz (427 500 psi). Also, the injection angle of pressurized water should be right angles to the radiator.
INSPECTION OF RADIATOR
1. Check of radiator cap
(1) Check the radiator cap by means of a radiator cap tester to see if the relief valve opens at a pressure of 0.6 - 1.05 kg/cmz (8.53 - 14.9 psi). If the radiator cap does not conform to the specification, replace the radiator cap.
(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 to function.
CO-10
Packing
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