2AZ FE Cooling

2AZ-FE COOLING – COOLING SYSTEM

CO–1

COOLING SYSTEM ON-VEHICLE INSPECTION 1.

CHECK CHEC K FOR FOR EN ENGI GINE NE COOL COOLAN ANT T LEA LEAKS KS NOTICE: Before performing each inspection, turn the A/C switch OFF. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Fill the radiat radiator or with with coolant coolant and attach attach a radiator radiator cap tester. (b) (b) Warm arm up up the the engi engine ne.. (c) Using a radiator radiator cap tester tester,, increase increase the pressur pressure e inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

2.

INSPECT INSPE CT ENG ENGINE INE COOL COOLANT ANT LEVEL LEVEL IN IN RESE RESERV RVOIR OIR (a) Check that the engine coolant coolant level level is betwe between en the the LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "TOYOTA "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, nonamine, non-nitrite and non-borate coolant with longlife hybrid organic acid technology to the FULL line. NOTICE: Do not substitute plain water for engine coolant.

3.

INSP INSPEC ECT T ENG ENGIN INE E COO COOLA LANT NT QUA QUALI LITY TY (a) (a) Re Remo move ve the the rad radia iato torr cap. cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there there are are any excessive excessive deposits deposits of rust rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. (c) (c) Inst Install all the the radi radiat ator or cap cap..

A135234

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CO–2

2AZ-FE COOLING – COOLING FAN SYSTEM

COOLING FAN SYSTEM 2AZ-FECOOLING ENGINE

PARTS LOCATION

COOLING FAN MOTOR

ENGINE ROOM RELAY BLOCK

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INSTRUMENT PANEL JUNCTION BLOCK -COOLING FAN RELAY -CDS FAN FUSE

-ECU IG FUSE NO. 1

-RDI FAN FUSE

A137456E02

CO–3

2AZ-FE COOLING – COOLING FAN SYSTEM

SYSTEM DIAGRAM

ECM

FAN No. 1 From Battery

3

RDI FAN

From Ignition Switch

ECU IG No. 1

5

22 A24 FANH

1

2

From Battery CDS FAN A6 A/C Condenser Fan Motor

2

FAN No. 3

5

3

1

2

4

2

1

A7 Radiator Fan Motor

FAN No. 2 1

3

5

1

2 21 A24 FANL

A137000

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CO–4

FAN SYSTEM 2AZ-FE COOLING – COOLING FAN

ON-VEHICLE INSPECTION 1.

INSPEC INSPECT T COOL COOLING ING FAN OPE OPERA RATIO TION N AT AT LOW LOW TEMPERATURES (Below 83 C (181 F)) (a) Turn Turn the the ig ignitio nition n switch switch to the the ON position. position. (b) Che Check ck that that the coolin cooling g fan fan stops stops.. If not, check the cooling fan relay and engine coolant temperature sensor, and check whether there is disconnection or an open circuit between them. (c) Disconnec Disconnectt the the engine coolant coolant temper temperature ature sensor sensor connector. (d) Che Check ck that that the coolin cooling g fan fan rotat rotates. es. If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the cooing fan relay and engine coolant temperature sensor. (e) Reconnect Reconnect the engine coolant coolant temper temperature ature sensor sensor connector. °

2.

INSPEC INSPECT T COOL COOLING ING FAN OPER OPERA ATION TION AT AT HIGH HIGH TEMPERATURES (Above 93 C (199 F)) (a) Start Start the engine, engine, and and raise raise the e engine ngine coolant coolant temperature to above 93 C (199 F). HINT: Engine coolant temperature is detected by the engine coolant temperature sensor on the water outlet. (b) Che Check ck that that the coolin cooling g fan fan rotat rotates. es. If not, replace the engine coolant temperature sensor. °

°

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°

°

°

CO–5

2AZ-FE COOLING – COOLANT

COOLANT ON-VEHICLE INSPECTION 1.

REMOVE REMOV E FRO FRONT NT WHEEL WHEEL OPENI OPENING NG EXTEN EXTENSIO SION N PAD RH

2.

REMOVE REMOV E FRO FRONT NT WHEEL WHEEL OPENI OPENING NG EXTEN EXTENSIO SION N PAD LH

3.

REMO RE MOVE VE EN ENGI GINE NE UN UNDE DER R COV COVER ER LH

4.

REMO RE MOVE VE EN ENGI GINE NE UN UNDE DER R COVE COVER R RH RH

5.

DRAIN DRAI N EN ENGI GINE NE COOL COOLAN ANT T NOTICE: Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Rem Remove ove the the radiato radiatorr cap sub-as sub-assem sembly bly from from the the radiator assembly. (b) Loosen the radiator radiator drain drain cock cock plug and cylinde cylinderr block drain cock plug, then drain the coolant.

Radiator Cap

CO Cylinder Block Drain Cock Plug Radiator Drain Cock Plug

A136224E04

HINT: Collect the coolant in a container and dispose d ispose of it according to the regulations in your area. 6.

ADD ENGINE ADD INE COOLAN LANT (a) Close the radiator radiator drain drain cock plug and 2 cylinder cylinder block drain cock plugs. Torque: 13 N*m (130 (130 kgf*cm, kgf*cm, 9 ft.*lbf) ft.*lbf) for cylinder block drain cock plug

CO–6

2AZ-FE COOLING – COOLANT

(b) Slowly Slowly fill the radiato radiatorr with TOYOT TOYOTA Super Long Life Life Coolant (SLLC). Specified capacity: 6.2 liters (6.6 US qts, 5.5 lmp. qts) HINT: • TOYOT TOYOTA A vehicl vehicles es are fill filled ed with with TOYOT TOYOTA A SLLC at the factory. factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). • Cont Contact act your TOYOT TOYOTA dealer dealer for further further detail details. s. (c) Slowly pour coolant coolant into into the the radiato radiatorr reservoir reservoir tank until it reaches the FULL line. (d) Press the inlet and o outlet utlet radiator radiator hoses hoses several several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. (e) Install Install the the radiator radiator cap sub-ass sub-assembly embly and reserv reservoir oir tank cap. (f) (f) Start tart the the eng engin ine, e, a and nd war warm m it up. up. HINT: Adjust the air conditioner set temperature to MAX (HOT). (g) Stop Stop the the engine, engine, and and wait wait until until the the engine engine coolant coolant cools down. (h) Add e engine ngine coolant coolant to the FULL FULL lline ine on on the radiator radiator reservoir.

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7.

CHEC CH ECK K FOR FOR EN ENGI GINE NE COOL COOLAN ANT T LEA LEAKS KS

8.

INST INSTAL ALL L ENG ENGIN INE E UND UNDER ER COVE COVER R RH RH

9.

INST INSTAL ALL L ENG ENGIN INE E UND UNDER ER COVE COVER R LH LH

10. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING EXTENSION EXTENSION PAD PAD LH 11. 11. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING EXTENSION EXTENSION PAD PAD RH

CO–7

2AZ-FE COOLING – WATER WATER PUMP

WATER WATER PUMP ENGINE 2AZ-FE COOLING

COMPONENTS 64 (653, 47)

ENGINE MOVING CONTROL ROD SUB-ASSEMBLY SUB-ASSEMBLY

52 (531, 38)

64 (653, 47)

NO. 2 ENGINE MOUNTING BRACKET RH

NO. 2 ENGINE MOUNTING STAY RH

V-RIBBED BELT

9.8 (100, 7 ) 8.4 (86, 74 in.*lbf)

52 (530, 38)

21 (215, 16)

CO GENERATOR ASSEMBLY

ENGINE UNDER COVER RH FRONT FENDER APRON SEAL RH

ENGINE UNDER COVER LH

FRONT WHEEL OPENING EXTENSION PAD LH FRONT WHEEL OPENING EXTENSION PAD RH N*m (kgf*cm, ft.*lbf) : Specified torque A136149E02

CO–8


CLAMP BRACKET

9.0 (92, 80 in.*lbf)

9.0 (92, 80 in.*lbf)

26 (265, 19) 26 (265, 19)

WATER PUMP PULLEY

WATER WA TER PUMP PU MP ASSEMBLY ASSEM BLY

N*m (kgf*cm, ft.*lbf) : Specified torque A136759E05

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CO–9

REMOVAL 1.

DISCONNE DISCO NNECT CT CABL CABLE E FROM FROM NEGA NEGATIV TIVE E BATTE BATTER RY TERMINAL

2.

REMOVE REMOV E FRO FRONT NT WHEEL WHEEL OPENI OPENING NG EXTEN EXTENSIO SION N PAD RH

3.

REMOVE REMOV E FRO FRONT NT WHEEL WHEEL OPENI OPENING NG EXTEN EXTENSIO SION N PAD LH

4.

REMO RE MOVE VE EN ENGI GINE NE UN UNDE DER R COVE COVER R RH RH

5.


6.

DRAI DR AIN N ENG ENGIN INE E COO COOLA LANT NT (Se (See e pag page e CO-5 CO-5))

7.

REMO RE MOVE VE FRON FRONT T FEND FENDER ER APR APRON ON SEA SEAL L RH

8.

REMOVE REMOV E NO. NO. 2 ENGI ENGINE NE MOU MOUNTI NTING NG ST STAY RH (Se (See e page EM-95 EM-95))

9.

REMOVE REMOV E ENGI ENGINE NE MOVING MOVING CONTR CONTROL OL ROD ROD SUBSUBASSEMBLY ASSEMBLY (See page EM-95 EM-95))

10. REMOVE REMOVE NO. NO. 2 ENGINE ENGINE MOUNTI MOUNTING NG BRA BRACKET CKET RH RH (See page EM-96 EM-96)) 11. REMOVE REMOVE V-RIB V-RIBBED BED BELT BELT (See page page EM-6 EM-6)) 12. REMOVE GENERATOR GENERATOR ASSEMBLY ASSEMBLY (See (See page page CH-11 CH-11)) 13. REMOVE REMOVE WA WATER PUMP PULLEY PULLEY (a) Using SST, SST, remove remove the the 4 bolts bolts and water pump pulley. SST 09960-1 09960-1001 0010 0 (09962 (09962-01 -01000 000,, 099 0996363-007 00700) 00)

SST

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A098715E03

14. REMOVE REMOVE WA WATER PUMP PUMP ASSEMBL ASSEMBLY Y (a) Remove Remove the clamp of the the cranksh crankshaft aft position position sensor sensor from the water pump. (b) Disconnect Disconnect the wire of the the cranksh crankshaft aft position position sensor from the clamp bracket.

A094516E01

CO–10


(c) Rem Remove ove the the 4 bolts bolts,, 2 nuts nuts and clam clamp p bracke bracket. t. Clamp Bracket

B012052E03

(d) Using a screwdri screwdriver ver,, pry pry between between the water water pump and cylinder block, and then remove the water pump. HINT: Tape the screwdriver tip before use. NOTICE: Be careful not to damage the contact surfaces of the water pump and cylinder block. A129792

Air Hole

INSPECTION Drain Hole

1.

INSP INSPEC ECT T WA WATER TER PUMP PUMP ASS ASSEM EMBL BLY Y (a) Visually Visually check the d drain rain hole hole and and air hole for for coolant coolant leakage. If leakage is found, replace the water pump assembly.

A128603E01

(b) Turn Turn the pulley, pulley, and then check check that that the the water water pump pump bearing moves smoothly without making a "click" sound. If it does not move smoothly, smoothly, replace the water pump assembly.

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A112198


CO–11

INSTALLATION 1.

Seal Diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)

A

A

INSTALL INST ALL WA WATER TER PUM PUMP P ASS ASSEM EMBL BLY Y (a) Rem Remove ove any any old seal seal packin packing g mat materi erial al from from the contact surface. (b) Apply a continuo continuous us line line of seal packin packing g as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.2 to 2.5 mm (0.09 to 0.10 in.) NOTICE: • Remove Remove any oil from the contact contact surface surface.. • The parts parts must must be set within within 3 minutes minutes after after applying seal packing. Otherwise, the material must be removed and reapplied.

A-A 0.5 to 1.0 mm (0.02 to 0.04 in.)

2.5 mm (0.10 in.) A094495E05

Clamp Bracket

(c) Insta Installll the wate waterr pump pump and clamp clamp brac bracket ket with with the the 4 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) in.*lbf)

CO B012052E03

(d) Install Install the the wire wire of the cranks crankshaft haft position position sensor sensor onto the clamp bracket. (e) Install Install the the clamp clamp of of the crankshaft crankshaft position position sensor sensor onto the water pump.

A094516

CO–12


2.

INST INSTAL ALL L WA WATER TER PUM PUMP P PUL PULLE LEY Y (a) Using SST, SST, install install the the water water pump pump pulley pulley with with the 4 bolts. SST 099 0996060-100 10010 10 (09962 (09962-01 -01000 000,, 099 0996363-007 00700) 00) Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) ft.*lbf)

3.

INST INS TALL GENE GENERA RATO TOR R ASSEMB ASSEMBL LY (See (See page page CH-19 CH-19))

4.

INST INS TALL V-RIBB -RIBBED ED BE BEL LT (Se (See e page page EM-6 EM-6))

5.

INSTALL NO. INST NO. 2 ENG ENGINE INE MOUNTI MOUNTING NG BRAC BRACKET KET RH (See page EM-118 EM-118))

6.

INSTALL EN INST ENGIN GINE E MOV MOVING ING CONTR CONTROL OL ROD SU SUBBASSEMBLY (See page EM-119 EM-119))

7.

INSTALL NO. INST NO. 2 ENG ENGINE INE M MOUN OUNTIN TING G STA STAY RH (Se (See e page EM-119 EM-119))

8.

CONNEC CONNECT T CABL CABLE E TO TO NEG NEGA ATIVE TIVE BA BATTER TTERY TERMINAL (See page EM-120 EM-120))

9.

ADD AD D ENG ENGIN INE E COO COOLA LANT NT (See (See page age CO-5 CO-5))

SST

A098715E02

10. CHECK CHECK FOR ENGINE ENGINE COOLAN COOLANT T LEAKS (See (See page page CO-1)) CO-1 11. INSTALL INSTALL ENGIN ENGINE E UNDER UNDER COVER COVER LH 12. INSTALL INSTALL ENGIN ENGINE E UNDER UNDER COVE COVER R RH 13. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING EXTENSION EXTENSION PAD PAD RH 14. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING EXTENSION EXTENSION PAD PAD LH

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CO–12

2AZ-FE COOLING – THERMOSTAT

THERMOSTAT 2AZ-FECOOLING ENGINE

COMPONENTS

WATER INLET

THERMOSTAT

9.0 (92, 80 in.*lbf)

GASKET

RADIATOR HOSE OUTLET

Non-reusable part

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CO–13


REMOVAL 1.

REMOVE REMOV E FRON FRONT T WHEE WHEEL L OPEN OPENIN ING G EXTE EXTENS NSION ION PAD LH

2.

REMOVE REMOV E FRON FRONT T WHEE WHEEL L OPEN OPENIN ING G EXTE EXTENS NSION ION PAD RH

3.


4.

REMO RE MOVE VE EN ENGI GINE NE UN UNDE DER R COV COVER ER RH

5.

DRAI DR AIN N EN ENGIN GINE E COO COOLA LANT NT (See (See page page CO-5 CO-5))

6.

DISCONNEC DISCON NECT T RADI RADIA ATOR TOR HOSE HOSE OUTLET OUTLET (See (See page page EM-96)) EM-96

7.

REMOV EMOVE E WATER TER INL INLET (a) Rem Remove ove the the 2 nuts and and discon disconnec nectt the wa water ter inlet inlet from the cylinder block.

8.

REMOV EMOVE E THER THERMO MOST STA AT (a) Rem Remove ove the the gaske gaskett from from the ther thermos mostat tat..

A112181

INSPECTION 1.

INSP INSPEC ECT T THER THERMO MOST STA AT (a) The valve opening opening tempera temperature ture is inscri inscribed bed o on n the the thermostat.

P013560E01

(b) Immerse Immerse the the the thermost rmostat at in water, water, and then gradually gradually heat the water. (c) Che Check ck the the valve valve openi opening ng tempe temperat rature ure of of the thermostat. Standard valve opening temperature: 80 to 84 C (176 to 183 F) If the valve opening temperature is not as specified, replace the thermostat. °

P000436E01

°

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CO–14


(d) Chec Check k tthe he valv valve e lif lift. t. Standard Standard valve lift: 10 mm (0.39 in.) or more at 95 C (203 F) If the valve lift is not as specified, replace the thermostat. (e) Che Check ck that that the the valve valve is full fully y closed closed when when the the thermostat is at low temperatures (below 77 C (171 F)). If it is not fully closed, replace the thermostat. °

°

°

Valve Lift A085445E04

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°

CO–15


INSTALLATION 1.

INST INSTAL ALL L THER THERMO MOST STA AT (a) Instal Installl a new gask gasket et onto onto th the e the thermo rmost stat. at. (b) Install Install the the thermost thermostat at with with the the jiggle jiggle valve valve upward. upward. HINT: The jiggle valve may be set to within 10 on either side of the prescribed position.

Upward

°

10° 10°

Jiggle Valve

A112199E02

2.

INST INSTAL ALL L WATER TER INLE INLET T (a) Instal Installl the wat water er inlet inlet with with the the 2 nuts nuts.. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

3.

CONNEC CONNECT T RADI RADIA ATOR TOR HOSE HOSE OUTLET OUTLET (See (See page page EM118)) 118

4.

ADD AD D ENG ENGIN INE E COO COOLA LANT NT (See (See page age CO-5 CO-5))

5.

CHECK CHEC K FOR FOR ENGIN ENGINE E COOL COOLAN ANT T LEAK LEAKS S (See (See pag page e CO-1)) CO-1

6.

INST INSTAL ALL L EN ENGI GINE NE UN UNDE DER R COVE COVER R LH

7.

INST INSTAL ALL L EN ENGI GINE NE UN UNDE DER R COVE COVER R RH

8.

INSTALL FRONT INST FRONT WHEEL WHEEL OPENIN OPENING G EXTEN EXTENSION SION PAD LH

9.

INSTALL FRONT INST FRONT WHEEL WHEEL OPENIN OPENING G EXTEN EXTENSION SION PAD RH

A112181

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CO–15

FAN MOTOR 2AZ-FE COOLING – COOLING FAN

COOLING FAN MOTOR

Cooling Fan Motor Side Connector:

ON-VEHICLE INSPECTION 1.

Positive (+)

Negative (-) A103699E02

COOL COOLIING FAN MOTO OTOR (a) Che Check ck that that the the mot motor or turns turns smoo smoothl thly y when when the battery is connected to the fan motor connector. (b) Measure Measure the the c current urrent while the motor is turning turning.. Standard current: With trailer hitch: 11.8 to 14.8 A at 20 C (68 F) Without trailer hitch: 7.9 to 10.9 A at 20 C (68 F) If the result is not as specified, replace the cooling fan motor. °

°

2.

Cooling Fan Motor Side Connector:

Positive (+)

Negative (-) A103699E02

°

°

NO. NO. 2 COO COOLI LING NG FAN MOT MOTOR (a) Che Check ck that that the the mot motor or turns turns smoo smoothl thly y when when the battery is connected to the fan motor connector. (b) Measure Measure the the c current urrent while the motor is turning turning.. Standard current: With trailer hitch: 7.9 to 10.9 A at 20 C (68 F) Without trailer hitch: 7.9 to 10.9 A at 20 C (68 F) If the result is not as specified, replace the cooling fan motor No. 2. °

°

°

°

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CO–16

2AZ-FE COOLING – COOLING COOLIN G FAN RELAY

1

COOLING COOLI NG FAN RELAY RELAY

2

ON-VEHICLE INSPECTION 5

3

1. 5

1

2 3

B060778E01

COO COOLING ING FA FAN RE RELAY LAY (a) Rem Remove ove the the relay relay from from the engin engine e room No. No. 2 relay relay block. (b) Mea Measur sure e the resi resista stance nce of of the rela relay y. Standard resistance

Tester Connection

Specified Condition

3-5

10 Ω or higher

3-5

Below 1 Ω (when battery voltage is applied to terminals 1 and 2)

If the result is not as specified, replace the relay. relay. (c) Install Install the the relay relay tto o the engine room relay block No. 2. 2. 1

4

2

4

3

5 5

1

2 3

A087121E01

COOL COOLIN ING G FAN FAN RE RELA LAY Y NO NO. 2 (a) Rem Remove ove the the relay relay from from th the e engine engine room room No. 2 relay relay block. (b) Mea Measur sure e the resi resista stance nce of of the rela relay y. Standard resistance

Tester Connection

Specified Condition

3-4

Below 1 Ω

3-5

10 Ω or higher

3-4

10 Ω or higher (when battery voltage is applied to terminals 1 and 2)

3-5


If the result is not as specified, replace the relay. relay. (c) (c) Inst Instal alll the the rela relay y.

CO

3.

3

5

1

2 5

1

2 3

B060778E45

COOL COOLIN ING G FAN FAN RE RELA LAY Y NO NO. 3 (a) Rem Remove ove the the relay relay from from th the e engine engine room room No. 2 relay relay block. (b) Mea Measur sure e the resi resista stance nce of of the rela relay y. Standard resistance

Tester Connection

Specified Condition

3-5

10 Ω or higher

3-5


If the result is not as specified, replace the relay. relay. (c) (c) Inst Instal alll the the rela relay y.

CO–17

2AZ-FE COOLING – RADIATOR

RADIATOR ENGINECOOLING 2AZ-FE

COMPONENTS

AIR CLEANER CAP SUB-ASSEMBLY SUB-ASSEMBLY

5.0 (51, 44 in.*lbf)

AIR CLEANER FILTER FILTER ELEMENT

x2

AIR CLEANER INLET ASSEMBLY ASSEMBLY

CO

ENGINE UNDER COVER RH

ENGINE UNDER COVER LH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH N*m (kgf*cm, ft.*lbf) : Specified torque A139342E01

CO–18


7.0 (71, 62 in.*lbf)

x4

RADIATOR RADIAT OR SUPPORT UPPER

HOOD LOCK ASSEMBLY

x2 7.5 (77, 66 in.*lbf)

HORN CONNECTOR

7.0 (71, 62 in.*lbf)

7.5 (77, 66 in.*lbf)

x2 x2

CO FRONT BUMPER ENERGY ABSORBER x2

x9

FRONT BUMPER ASSEMBLY


CO–19


RADIATOR RADIAT OR HOSE OUTLET RADIATOR RADIAT OR HOSE INLET

RADIATOR SUPPORT RADIATOR CUSHION

RADIATOR ASSEMBLY FAN MOTOR CONNECTOR FAN MOTOR WITH MOTOR RADIATOR SUPPORT RADIATOR LOWER

CO

5.0 (51, 44 in.*lbf)

x4

CONDENSER ASSEMBLY


CO–20


RADIATOR CAP SUB-ASSEMBLY FAN ASSEMBLY WITH MOTOR

RADIATOR TANK UPPER

O-RING

CORE SUB ASSEMBLY ASSEMBLY

15 (150, 11)

with AUTOMATIC TRANSAXLE O-RING

15 (150, 11)

OIL COOLER ASSEMBLY ASSEMBLY

O-RING

O-RING RADIATOR TANK LOWER

DRAIN PLUG

OIL COOLER PIPE

8.3 (85, 73 in.*lbf)

O-RING

Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque

A137802E02

ON-VEHICLE INSPECTION

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1.

1 2 3

4 A107446E01

CHECK RAD CHECK RADIA IATO TOR R CAP CAP SU SUBB-ASS ASSEM EMBL BLY Y (a) Mea Measur sure e the the valve valve open opening ing pressu pressure. re. (1) If there there are are water water stain stains s or foreig foreign n mat matter ter on on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. (2) Che Check ck that that rubb rubber er packi packings ngs 1, 1, 2 and and 3 are not not deformed, cracked or swollen. (3) Che Check ck that that rubb rubber er packi packings ngs 3 and 4 are are not not stuck together. (4) Apply Apply engin engine e coolan coolantt to rubbe rubberr packin packings gs 2 and 3 before using the radiator cap tester. tester. (5) When When using using the the cap test tester er,, tilt tilt it to 30 or more above the horizontal. °

CO–21


(6) Pump Pump the cap cap tester tester seve several ral time times, s, and and check check the maximum pressure *1. Pumping speed: 1 pumps every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criteria

Radiator Cap Tester

30° or more Radiator Cap A104601E03

Item

Specified Condition

Standard valve (for brand-new cap)

93.3 to 122.7 kPa (0.95 to 1.25 kgf/

Minimum standard valve (after using cap)

cm2, 13.5 to 17.8 psi) 78.5 kPa (0.8 kgf/cm2, 11.4 psi)

If the maximum pressure is less than the specified pressure for the minimum standard valve, replace the radiator cap sub-assembly. sub-assembly.

ON-VEHICLE CLEANING 1.

A073603

INSP INSPEC ECT T FINS FINS BLOC BLOCKA KAGE GE (a) If the the fins fins are are clogged, clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE: • If the the dist distanc ance e betwee between n the steam steam clea cleaner ner and and the core is too close, the fins may become damaged. Keep the following injection distance. Standard Injection Distance 300 mm (11.81 in.) 500 mm (19.69 in.)

Injection Pressure 2,942 to 4,903 kPa (30 to 50 kg/cm 2, 427 to 711 psi) 4,903 to 7,845 kPa (50 to 80 kg/cm2, 711 to 1,138 psi)

• If the fins are bent, bent, straig straighten hten them them with with a screwdriver or pliers. • Nev Never er apply apply water water direc directly tly onto onto the the elect electroni ronic c components.

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CO–22


REMOVAL 1.

DRA DR AIN EN ENGI GINE NE COOL COOLAN ANT T

2.

REMOVE REMO VE FRO FRONT NT WH WHEE EEL L OPE OPENI NING NG EXTE EXTENS NSIO ION N PAD LH

3.

REMOVE REMO VE FRO FRONT NT WH WHEE EEL L OPE OPENI NING NG EXTE EXTENS NSIO ION N PAD RH

4.

REMO RE MOVE VE EN ENGI GINE NE UN UNDE DER R COV COVER ER RH

5.


6.

REMOVE REMOVE AIR CLEANE CLEANER R CAP CAP SUB SUB-AS -ASSEMB SEMBL LY (See (See page ES-416 ES-416))

7.

REMOVE REMO VE AIR AIR CLE CLEAN ANER ER IN INLE LET T ASSE ASSEMB MBL LY (See (See page EM-94 EM-94))

8.

REMOVE REMO VE FRO FRONT NT BUM BUMPE PER R ASSE ASSEMB MBL LY (w/o (w/o Fog Fog Light) (See page ET-5 ET-5))

9.

REMOVE REMO VE FRO FRONT NT BU BUMPE MPER R ASS ASSEM EMBL BLY Y (w/ (w/ Fog Fog Light) (See page ET-6 ET-6))

10. REMOVE FRONT FRONT BUMPER BUMPER ENERGY ENERGY A ABSORB BSORBER ER 11. 11. SEPARA SEPARATE TE RADIATOR RADIATOR RESERVE RESERVE TANK TANK HOSE (a) Separate Separate the radiator radiator reserve reserve tank hose from the radiator assembly.

A135233

12. DISCONNECT DISCONNECT RADI RADIA ATOR HOSE INLET (a) Disconnec Disconnectt the radiator radiator hose hose inlet inlet from from the the radiator radiator assembly.

CO

A135240

13. DISCONNECT DISCONNECT RADI RADIA ATOR HOSE OUTLET OUTLET (a) Disconnec Disconnectt the radiator radiator hose hose out outlet let from from the the radiator radiator assembly.

A133364


CO–23

14. DISCONNEC DISCONNECT T OIL COOLER COOLER INLET INLET HOSE (for Automatic Transaxle) (a) Disconnect Disconnect the oil oil cooler cooler inlet inlet hose hose from from th the e radiator radiator assembly.

A133365

15. DISCONNECT DISCONNECT OIL COOLER COOLER OUTLET OUTLET HOSE (for Automatic Transaxle) (a) Disconnect Disconnect the oil cooler cooler outlet outlet hose hose ffrom rom the the radiator assembly.

A133366

16. REMOVE REMOVE RADIA RADIATOR TOR SUPP SUPPORT ORT UPPER UPPER (a) Discon Disconnec nectt the the horn horn conne connecto ctorr. (b) Rem Remove ove the the 3 bolts bolts and and separa separate te th the e hoo hood d lock lock assembly from the radiator support upper.

A135235

(c) Remove Remove the the clamp clamp and and separ separate ate the the hood hood lock lock control cable from the radiator support upper.

A135236

(d) Remove Remove the the 5 bolts and radiat radiator or support support upper. upper.

A135237

CO

CO–24


17. REMOVE REMOVE RADIA RADIATO TOR R ASSEMBL ASSEMBLY Y (a) Rem Remove ove the the 3 clamp clamps s and 2 connec connector tors. s.

A135241

(b) Remove Remove the the 4 bolts bolts and separ separate ate the the condens condenser er assembly from the radiator assembly. assembly.

A135239

(c) Rem Remove ove the the radiato radiatorr assemb assembly ly from from the body body..

A135238

18. REMOVE FAN ASSEMBL ASSEMBLY WITH WITH MOTOR MOTOR (a) Release Release th the e 3 snap snap fits fits and lift lift the fan fan assembl assembly y with motor from the radiator.

CO

Guide Snap Fit A136226E01

19. REMOVE RADIA RADIATOR TOR SUPPORT SUPPORT CUSHION CUSHION (a) Remo Remove ve tthe he 2 radiator radiator support support cushions cushions from the radiator assembly.

Radiator Support Cushion

A133371E02


CO–25

20. REMOVE REMOVE RADIA RADIATOR TOR SUPP SUPPORT ORT LOWER LOWER (a) Rem Remove ove the the 2 radiat radiator or suppo support rt lower lowers s from from the radiator assembly.

Radiator Support Lower

A133371E03

CO

CO–26


DISASSEMBLY 1.

REMOVE DRA REM RAIN IN PLUG (a) Re Remo move ve the the dra drain in plug plug.. (b) (b) Re Remo move ve the the O-r O-rin ing. g.

2.

REMOVE REMO VE RA RADI DIA ATOR TAN ANK K UPP UPPER ER (a) Install Install the the claw claw to the overhau overhaull handle, handle, insert inserting ing it in the hole in part A as shown in the illustration. SST 092 0923030-010 01010 10 (09231 (09231-01 -01010 010,, 092 0923131-010 01030) 30) (b) While gripping gripping th the e han handle, dle, adjust adjust the stoppe stopperr bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.

Stopper Bolt Part A Dimension B

0.2 to 0.3 mm

SST

Claw Overhaul Handle

A104619E05

(c) Using Using SST to to releas release e the caulk caulking ing,, grip grip the handl handle e until stopped by the stopper bolt. SST 092 0923030-010 01010 10 (09231 (09231-01 -01010 010,, 092 0923131-010 01030) 30)

Tank Lock Plate SST

CO Stopper Bolt A128137E02

(d) Lightly Lightly tap tap the the bracket bracket of the the radiator radiator (or radiato radiatorr hose inlet or outlet) with a soft-faced hammer and remove the tank. (e) (e) Re Remo move ve the the O-r O-rin ing. g. 3.

Tap

A128138E01

REMOVE REMO VE RA RADI DIA ATOR TAN ANK K LOW LOWER ER HINT: Removal procedure of the radiator tank lower is the same as that of the radiator tank upper.


4. (D)

(C)

(A) (A) (B)

Lower Tank

(C)

CO–27

REMOVE REMO VE OIL OIL COO COOLE LER R ASS ASSEM EMBL BLY Y (a) Rem Remove ove the screw screw and and cool cooler er pipe pipe (A). (A). (b) Rem Remove ove the nut and p plat late e washe washerr (B). (B). (c) (c) Re Remo move ve the the oil oil coo coole lerr (C). (C). (d) Rem Remove ove the the 2 O-rin O-rings gs from from the the oil cool cooler er (D). (D).

(B)

A128140E02

Lock Plate

Lock Plate

INSPECTION 1.

Core A087087E06

INS NSP PECT LO LOCK PLATE (a) Inspec Inspectt the the lock lock plat plate e for for damage damage.. HINT: • If the sides sides of of the the lock lock plat plate e groov groove e are are deformed, reassembly of the tank will be impossible. Therefore, first correct the shape of the lock plate groove with pliers or a similar object, if necessary. • Wate aterr leakage leakage will will resul resultt if the the bot bottom tom of of the lock lock plate groove is damaged or dented. Repair or replace the lock plate if necessary. necessary. NOTICE: The radiator can onl only y be recaulked 2 times, After recaulking 2 times, the radiator core must be replaced.

REASSEMBLY (D)

(C)

(A)

1. (A) (B)

Lower Tank

(B) (C)

A128140E02

INST INSTAL ALL L OIL OIL COOL COOLER ER ASS ASSEM EMBL BLY Y (a) Clean the O-ring O-ring contact contact surfaces surfaces of of the the lower lower tank tank and oil cooler (D). (b) Insta Installll 2 new O-ri O-rings ngs to to the oil oil coole coolerr (C). (c) Insta Installll the the oil cooler cooler to to the the lower lower tank tank.. (d) Insta Installll the the plate plate washer washer and n nut ut (B). (B). Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) in.*lbf) (e) Insta Installll the cooler cooler pipe pipe ((A). A). Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) (f) (f) Inst Instal alll the the scre screw w ((A) A)..

CO

CO–28


2. Stopper Bolt Part A Dimension B

INST INSTAL ALL L RADI RADIA ATOR TOR TAN TANK K UPPE UPPER R (a) Install Install the the punch punch assembl assembly y to the overhau overhaull handle, handle, inserting it in the hole in part A as shown in the illustration. SST SST 0923 092300-01 0101 010, 0, 0923 092311-14 1401 010 0 (b) While gripping gripping th the e han handle, dle, adjust adjust the stoppe stopperr bolt so that dimension B is as shown in the illustration. Dimension B: 8.4 mm (0.331 in.)

SST

Punch Assembly Overhaul Handle

A104624E02

○ Normal

X Twisted

(c) After After checki checking ng that that there there are no no foreign foreign objects objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

CO X Twisted O-Ring

A104623E03

CORRECT Tank WRONG

Tap

Lock Plate A128141E01

(d) Install Install the the tank tank without without damagi damaging ng the the O-ring. O-ring. (e) Tap the lock plate plate with a soft-face soft-faced d hammer hammer so that there is no gap between the lock plate and the tank.


(f) 5

3

7 2

1 6

4

8

SST Lock Plate Stopper Bolt

Tank

CO–29

Lightl Lightly y press press SST SST again against st the the lock lock plate plate in in the order order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. HINT: • Do n not ot tap tap the the areas areas p prot rotrud ruding ing arou around nd the the pipes, pipes, brackets or tank ribs. • The dott dotted ed circle circles s shown shown in the the illus illustra tratio tion n and parts of the oil cooler near the dotted circles cannot be tapped with the SST. SST. Use pliers or similar objects and be careful not to damage the core plates.

A129608E01

(g) Check the lock plate height (H) afte afterr complet completing ing caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height range, adjust the stopper bolt of the handle and caulk again.

H

3.

INST INSTAL ALL L RADI RADIA ATOR TOR TAN TANK K LOWE LOWER R SST SST 0923 092300-01 0101 010, 0, 0923 092311-14 1401 010 0 HINT: Removal procedure of the lower radiator tank is the same as that of the upper radiator tank.

4.

INS NST TALL ALL DR DRAIN AIN PL PLUG (a) Insta Installll a new new O-ri O-ring ng to to the the drain drain plug. plug. (b) (b) Inst Install all the the dra drain in plug. plug.

5.

INSP INSPEC ECT T FOR FOR WATER TER L LEA EAKS KS (a) Plug the the inlet inlet and and outlet outlet pipes pipes of of the radiator radiator with with SST. SST 09230-01010 (b) Using the radiato radiatorr cap tester tester, apply pressure pressure to the radiator. Test Test pressure: pressu re:

A128142E02

177 kPa (1.8 kgf/cm2, 26 psi) (c) Submer Submerge ge the the radiat radiator or in w wate aterr.

SST A128143E03

CO

CO–30


(d) (d) Insp Inspec ectt for for lea leaks ks.. HINT: On radiators with resin tanks, there is clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.

Tank

Lock Plate O-Ring A087096E02

INSTALLATION Radiator Support Lower

1.

INSTALL RAD INST RADIA IATO TOR R SUPPO SUPPORT RT LOWER LOWER (a) Install Install the the 2 radiator radiator support support lowers lowers to the radiato radiatorr assembly.

2.

INSTALL RAD INST RADIA IATO TOR R SUP SUPPOR PORT T CUSH CUSHIO ION N (a) Install Install the the 2 radiato radiatorr support support cushion cushions s to the the radiator radiator assembly.

3.

INSTALL FAN AS INST ASSE SEMBL MBLY Y WITH WITH MOTO MOTOR R (a) Install Install the the fan fan assembly assembly with motor motor to the radiato radiatorr with the 2 guides at the bottom and 3 snap fits on the top.

4.

INST INSTAL ALL L RADI RADIA ATOR TOR ASSE ASSEMB MBL LY (a) Insta Installll the the radia radiator tor to the the body body..

A133371E03

Radiator Support Cushion

A133371E02

CO Guide Snap Fit A136226E01

A135238


CO–31

(b) Install Install the the condense condenserr assembly assembly with the 4 bolts. bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) in.*lbf)

A135239

(c) Connec Connectt the 2 fan moto motorr connec connector tors s and the the 3 clamps.

A135241

5.

INSTALL RAD INST RADIA IATO TOR R SU SUPP PPORT ORT UP UPPE PER R (a) Install Install the the radiator radiator support support upper upper with with the the 5 bolts. bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) in.*lbf)

A135237

(b) Install Install the the hood hood lock lock control control cable assembly assembly to to the radiator support upper with the clamp.

A135236E01

(c) Insta Installll the the hood lock lock asse assembl mbly y to the the radiato radiatorr support upper with the 3 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) in.*lbf) (d) Con Connec nectt the the horn horn c conn onnect ector or..

A135235

CO

CO–32


6.

CONN CONNEC ECT T OIL OIL COOL COOLER ER OUT OUTLE LET T HOSE HOSE (fo (forr Automatic Transaxle) (a) Conne Connect ct tthe he oil cooler outlet hose to the the radiator radiator assembly.

7.

CONNEC CONNECT T OIL OIL COOLE COOLER R INLE INLET T HOSE HOSE (for (for Autom Automat atic ic Transaxle) (a) Conne Connect ct tthe he oi oill cooler cooler inlet hose to the the radiato radiatorr assembly.

8.

CONN CONNEC ECT T RADI RADIA ATOR TOR HOS HOSE E OUT OUTLE LET T (a) Conne Connect ct tthe he radiato radiatorr hose hose outlet outlet tto o the the radiator radiator assembly.

9.

CONN CONNEC ECT T RAD RADIA IATO TOR R HOS HOSE E INL INLET ET (a) Conne Connect ct tthe he radiato radiatorr hose hose inlet inlet to to the the radiato radiatorr assembly.

A128129

A128128

A128127

CO

A135240

10. CONNECT RADIA RADIATOR TOR RESERVOIR RESERVOIR TANK HOSE HOSE (a) Conne Connect ct tthe he radiato radiatorr reservoir reservoir tank hose to the the radiator assembly. 11. 11. INSTALL INSTALL AIR CLEANER INLET INLET ASSEMBL ASSEMBLY Y (See page EM-120)) EM-120 12. INSTALL INSTALL AIR CLEANER CAP SUB-ASSE SUB-ASSEMBL MBLY Y (See (See page ES-419 ES-419)) 13. ADD ENGINE ENGINE COOL COOLANT ANT (See (See page page CO-5 CO-5)) A135233


CO–33

14. CHECK CHECK FOR ENGINE ENGINE COOLAN COOLANT T LEAKS (See (See page page CO-1)) CO-1 15. INSTALL INSTALL ENGIN ENGINE E UNDER UNDER COVER COVER LH 16. INSTALL INSTALL ENGIN ENGINE E UNDER UNDER COVER COVER RH 17. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING OPENING EXTENSION EXTENSION PAD PAD RH 18. INSTALL INSTALL FRONT FRONT WHEEL WHEEL OPENING OPENING EXTENSION EXTENSION PAD PAD LH

CO

2AZ FE Cooling

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