Chapter 2 COOLING SYSTEM

1.

Specifications.......................................................................................... 2-1

2.

Structure .................................................................................................. 2-2

3.

Removal and Installation........................................................................ 2-3

3.1
3.2
3.3

4.

Fan Belt Removal .................................................................................................... 2-3

Suggestions for Removal ........................................................................................ 2-3
Installation ............................................................................................................... 2-3

Inspection and Adjustment .................................................................... 2-4

4.1
4.2
4.3
4.4
4.5
4.6

Fan Belt Inspection.................................................................................................. 2-4

Fan Belt Tension ..................................................................................................... 2-4
Connecting Hoses ................................................................................................... 2-4
Unit Layout .............................................................................................................. 2-5
Coolant .................................................................................................................... 2-5
Radiator Cap ........................................................................................................... 2-5

COOLING SYSTEM
Chapter 2 COOLING SYSTEM

1. Specifications
Items
Cooling method
Cooling system

Radiator

Truck class
1 ton class

2 ton class

3 ton class

Water-cooled, forced circulation

Corrugated fin (pressure) type

Water pump

Centrifugal type

Thermostat

Wax pellet type

2-1

COOLING SYSTEM

2. Structure
Fan (directly coupled to engine)

Radiator
Shroud

Hose layout

K21E, K25E
engines
Lower hose

Reservoir tank
K21E, K25E
Upper hose

2-2

217092

COOLING SYSTEM

3. Removal and Installation

3.1 Fan Belt Removal

Engine

1
217091

1 Tension pulley assembly, bolt

2 Belt

3.2 Suggestions for Removal

(1) Loosen the tension pulley lock bolt by three or
four turns.
If the bolt is loosened insufficiently, the tension
pulley will not move.
Note: Do not loosen the lock bolt to such an extent
that the bolt would be removed.

Fan pulley

Tension pulley

(2) Move the tension pulley fully toward the fan, then
remove the belt.

217093

3.3 Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it generates unusual noises.
(2) After installing the belt, push it to make sure that
the tension pulley moves, then tighten the pulley
lock bolt firmly.

2-3

COOLING SYSTEM

4. Inspection and Adjustment

4.1 Fan Belt Inspection
(1) Check the belt for contamination from oil, grease
or dust. Replace the belt if required. When the
contamination is slight, clean the belt with a rag or
paper towel. Do not use gasoline, oil or any other
solvent to clean the belt.
(2) During the engine overhaul or belt tension adjustment, check the condition of the belt. Replace the
belt if it has any damage.

4.2 Fan Belt Tension

Apply force of 98 N (10 kgf) [22.0 lbf] perpendicularly
to the belt midway between the fan pulley and tension
pulley. Adjust the belt tension between 11 to 13 mm
(0.43 to 0.51 in.).

Fan pulley

Tension pulley

217094

4.3 Connecting Hoses

When connecting the hoses to the radiator, fit their
ends fully on the fittings and secure them with clamps.
Make sure that each hose is correctly connected and
over the flare of the fitting.

Hose

213455

2-4

COOLING SYSTEM

4.4 Unit Layout

217095

4.5 Coolant
Fill the radiator with coolant containing antifreeze.
After starting the engine and letting it warm up during
operation, check for abnormal noises. Check the coolant level in the reserve tank to ensure it meets the
specification.
Coolant quantity
Unit: liter (cu.in.)
Truck class

Item

1 ton class

2 ton class

3 ton class

Reservoir tank (FULL level)

0.65 (39.7)

0.65 (39.7)

0.65 (39.7)

Total quantity of coolant

(including coolant in hoses)

6.8 (415.0)

7.4 (451.6)

8.7 (530.9)

4.6 Radiator Cap

Unit: kPa (kgf/cm2) [psi]
Opening pressure

Vacuum valve

88 14.7
(0.90 0.15)
[12.8 2.1]
0 to 4.9
(0 to 0.05)
[0 to 0.71]

2-5