Coolant

CO1
COOLING (5SFE) COOLANT
COOLANT
CO06603
INSPECTION
HINT: Check the coolant level when the engine is cold. 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the LOW and FULL lines. If low, check for leaks and add Toyota Long Life Coolant or equivalent up to the FULL line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap.
Author :
Date :
1575
CO2
COOLING (5SFE) COOLANT
CO06703
REPLACEMENT
1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
(b)
Radiator Drain Plug
Engine Drain Plug

Z18990
Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug (on the left rear of the cylinder block), and drain the coolant. (c) Close the drain plugs. Torque: 25 Nm (250 kgfcm, 18 ftlbf) for engine 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant. z Use of improper coolants may damage engine cooling system. z Use Toyota Long Life Coolant or equivalent and mix it with plan water according to the manufacturers directions. z Using of coolant which includes more than 50 % (freezing protection down to 35C (31F) or 60 % (freezing protection down to 50C (58F)) of ethyleneglycol is recommended but not more than 70 %. NOTICE: z Do not use an alcohol type coolant or plain water alone. z The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity:
w/ Oil cooler w/o Oil cooler 6.9 litters (7.3 US qts, 6.1 lmp. qts) 6.2 litters (6.5 US qts, 5.4 lmp. qts)
(b) (c) (d) 3.
Install the radiator cap. Start the engine, and bleed the cooling system. Refill the radiator reservoir with coolant until it reaches the FULL line. CHECK FOR COOLANT LEAKS
Author :
Date :
1576
CO3
COOLING (5SFE) WATER PUMP
WATER PUMP
CO06803
COMPONENTS
64 (650, 47) 64 (650, 47)
Engine Moving Control Rod

52 (530, 38)
Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt w/ Oil Cooler A/C Compressor Connector A/C Compressor
Cylinder Block Insulator
PS Pump Drive Belt
RH Front Fender Apron Seal
Nm (kgfcm, ftlbf) : Specified torque
S05543
Author :
Date :
1577
CO4
Generator Wire * Gasket Generator Connector Generator Wire Clamp No.2 Timing Belt Cover No.1 Timing Belt Cover Crankshaft Pulley * Gasket Wire Clamp Timing Belt Timing Belt Guide HighTension Cord
Spark Plug
18 (180,13)
Wire Clamp
108 (1,100, 80)
Wire Clamp z ORing Wire Clamp No.1 Idler Pulley

42 (425,31)
Tension Spring z ORing No.2 Idler Pulley z Gasket

42 (425,31)
Generator Drive Belt Adjusting Bar Wire Clamp
Water Pump and Water Pump Cover Assembly Lower Radiator Hose
Crankshaft Position Sensor Connector Water Pump Cover z Gasket Water Pump Nm (kgfcm, ftlbf) : Specified torque * Replace only if damaged z Nonreusable part
S05939
Author :
Date :
1578
CO5
CO06904
REMOVAL
1. 2. 3. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM17) DISCONNECT LOWER RADIATOR HOSE FROM WATER OUTLET 4. REMOVE TIMING BELT TENSION SPRING Loosen the No.1 idler pulley bolt, and remove the tension spring. 5. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 6. w/ Oil Cooler: REMOVE A/C COMPRESSOR (See page EM69)
7. (a) (b) (c)
REMOVE GENERATOR DRIVE BELT ADJUSTING BAR Disconnect the engine wire clamp from the adjusting bar. Disconnect the crankshaft position sensor connector from the bracket on the adjusting bar. Remove the bolt and adjusting bar.
S05599
8. (a)
REMOVE WATER PUMP AND WATER PUMP COVER ASSEMBLY Remove the 2 nuts holding the water pump to the water bypass pipe.
S05924
(b)
1 3
Remove the 3 bolts in the sequence shown.
2
S05963
Author :
Date :
1579
CO6
Disconnect
(c)
Disconnect the water pump cover from the water bypass pipe, and remove the water pump and water pump cover assembly. (d) Remove the gasket and 2 Orings from the water pump and water bypass pipe. 9. REMOVE WATER PUMP FROM WATER PUMP COVER Remove the 3 bolts, water pump and gasket.
S05965
Author :
Date :
1580
CO7
CO06A03
Turn
INSPECTION
1. INSPECT WATER PUMP (a) Visually check the air hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT TIMING BELT COMPONENTS (See page EM22)
Air Hole
S01486
Author :
Date :
1581
CO8
CO06B03
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER Install a new gasket and the water pump with the 3 bolts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf)
N00918
Connect
2. (a) (b) (c) (d)

S06015
INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY Install new Oring and gasket to water pump cover. Install a new Oring to the water bypass pipe. Apply soapy water to the Oring on the water bypass pipe. Connect the water pump cover to the water bypass pipe. Do not install the nuts yet.
(e)
3 1
Install the water pump with the 3 bolts. Tighten the bolts in the sequence shown. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf)
2
Z19283
(f)
Install the 2 nuts holding the water pump cover to the water bypass pipe. Torque: 9.3 Nm (95 kgfcm, 82 in.lbf)
S05924
3. (a) (b) (c) 4.

S05599
5.
INSTALL GENERATOR DRIVE BELT ADJUSTING BAR Install the adjusting bar with the bolt. Torque: 22 Nm (224 kgfcm, 16 ftlbf) Install the engine wire clamp to the adjusting bar. Install the crankshaft position sensor connector to the bracket on the adjusting bar. w/ Oil Cooler: INSTALL A/C COMPRESSOR (See page EM75) INSTALL NO.2 IDLER PULLEY (See page EM23)
Author :
Date :
1582
CO9
6. 7. 8. 9. 10.
INSTALL TIMING BELT TENSION SPRING (See page EM23) CONNECT LOWER RADIATOR HOSE TO WATER INLET INSTALL TIMING BELT (See page EM23) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS
Author :
Date :
1583
CO10
COOLING (5SFE) THERMOSTAT
THERMOSTAT
CO06C03
COMPONENTS
w/ Oil Cooler
Oil Filter
Thermostat z Gasket Water Inlet
z Nonreusable part
S05299
Author :
Date :
1584
CO11
CO06D03
REMOVAL
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. w/ Oil Cooler: REMOVE OIL FILTER (See page LU2)
3. (a) (b) (c)
REMOVE WATER INLET AND THERMOSTAT Remove the 2 nuts, and disconnect the water inlet from the water pump cover. Remove the thermostat. Remove the gasket from the thermostat.
S05322
Author :
Date :
1585
CO12
INSPECTION
INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature.
CO06E03
P13560
Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 84C (176 183F) If the valve opening temperature is not as specified, replace the thermostat.
(a)
P00436
Check the valve lift. Valve lift: 8 mm (0.31 in.) or more at 95C (203F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40C (104F)). If not closed, replace the thermostat.
Valve Lift
P24125
(c)
Author :
Date :
1586
CO13
CO0SN01
5 5
Protrusion
INSTALLATION
1. (a) (b) PLACE THERMOSTAT IN WATER INLET Install a new gasket to the thermostat. Align the jiggle valve of the thermostat with the protrusion of the water inlet, and insert the thermostat in the water inlet.
Jiggle Valve
P13611
HINT: The jiggle valve may be set within 5 of either side of the prescribed position. 2. INSTALL WATER INLET AND THERMOSTAT Install the water inlet and thermostat with the 2 nuts. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 3. w/ Oil Cooler: INSTALL OIL FILTER (See page LU2) 4. FILL WITH ENGINE COOLANT 5. START ENGINE AND CHECK FOR COOLANT LEAKS 6. CHECK ENGINE OIL LEVEL
S05322
Author :
Date :
1587
CO14
COOLING (5SFE) RADIATOR
RADIATOR
CO06G03
ONVEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core.)
Author :
Date :
1588
CO15
CO06H04
ONVEHICLE INSPECTION
1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
Radiator Cap Tester
30 or More Radiator Cap

Z00570
Radiator Cap Tester
B06362
2. INSPECT RADIATOR CAP NOTICE: z If the radiator cap has contaminations, always rinse it with water. z Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. z When performing steps (a) and (b) below, keep the tester at an angle of over 30 above the horizontal. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester, and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 74 103 kPa (0.75 1.05 kgf/cm2, 10.7 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2, 8.5 psi) HINT: Use the testers maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator with coolant, and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP
Author : Date : 1589
CO16
CO06I03
COMPONENTS
Upper Radiator Support No.2 Electric Cooling Fan Connector Radiator Assembly Radiator Reservoir Hose Upper Radiator Support
Lower Radiator Support
No.1 Electric Cooling Fan Connector ECT Switch Connector for Electric Cooling Fan
Lower Radiator Hose Upper Radiator Hose
Oil Cooler Hose for A/T
S05951
Author :
Date :
1590
CO17
Lower Radiator Hose
ECT Switch Connector for Electric Cooling Fan
No.2 Electric Cooling Fan
Wire Clamp Radiator
No.1 Electric Cooling Fan
Oil Cooler Hose for A/T
S05948
Radiator Cap Upper Tank z ORing A/T z ORing Plate Washer Nut Pipe Oil Cooler z ORing z ORing Nut Plate Washer
Core
z ORing ECT Switch for Electric Cooling Fan Lower Tank Drain Plug z ORing z Nonreusable part
S05240
Author :
Date :
1591
CO18
CO06J04
REMOVAL
1. 2. (a) (b) (c) (d) (e) (f) (g) DRAIN ENGINE COOLANT REMOVE RADIATOR ASSEMBLY Disconnect the No.1 electric cooling fan connector. Disconnect the No.2 electric cooling fan connector. Disconnect the ECT switch connector for the electric cooling fan. Disconnect the upper radiator hose from the radiator. Disconnect the lower radiator hose from the water inlet. Disconnect the radiator reservoir hose from the radiator. A/T: Disconnect the 2 oil cooler hoses from the oil cooler pipes.
(h) (i) (j) (k) (l)
S05955
Remove the 2 bolts and 2 upper radiator supports. Remove the radiator assembly. Remove the 2 lower radiator supports. Remove the lower radiator hose from the radiator. A/T: Remove the 2 oil cooler hoses from the radiator. 3. REMOVE NO.1 ELECTRIC COOLING FAN FROM RADIATOR (a) Disconnect the ECT switch connector for the cooling fan. (b) Disconnect the ECT switch wire clamp for the cooling fan from the bracket of the radiator. (c) Remove the 2 bolts and cooling fan. 4. REMOVE NO.2 ELECTRIC COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan.
Author :
Date :
1592
CO19
CO06K03
DISASSEMBLY
1. (a) (b) 2. (a) (b) REMOVE ECT SWITCH Remove the ECT switch. Remove the Oring. REMOVE DRAIN PLUG Remove the drain plug. Remove the Oring.
Part A
3.
Dimension B SST
Stopper Bolt
Claw
Overhaul Handle Tank
CO1205
ASSEMBLE SST SST 0923001010 (a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension: 0.2 0.3 mm (0.008 0.012 in) NOTICE: If this adjustment is not done the claw may be damaged. 4. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 0923001010
SST
Lock Plate
Stopper Bolt
S04699
5. REMOVE TANKS AND ORINGS Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a softfaced hammer, and remove the tank and the Oring.
Tap
S04703
6. (a) (b) (c)
A/T: REMOVE OIL COOLER FROM LOWER TANK Loosen the nut, and remove the cooler pipe. Remove the 2 nuts and plate washers. Remove the oil cooler and 2 Orings.
S04705
Author :
Date :
1593
CO20
CO06L04
Pipe 18 Downward
REASSEMBLY
1. (a) (b) A/T: INSTALL OIL COOLER TO LOWER TANK Install 2 new Orings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) Install the cooler pipe in the direction indicated in the illustration. Torque: 14.7 Nm (150 kgfcm, 11 ftlbf)
(c)
S05307
Lock Plate
Lock Plate
Core
CO1267
f Normal X Twisted
2. INSPECT LOCK PLATE FOR DAMAGE HINT: z If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. z Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 3. INSTALL NEW ORINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new Oring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
ORing X Twisted
CO0317
CORRECT
Tank
(b) (c)
Install the tank without damaging the Oring. Tap the lock plate with a softfaced hammer so that there is no gap between it and the tank.
WRONG Tap
Lock Plate
S04698
Author :
Date :
1594
CO21
4.
Part A
(a)
Dimension B SST
(b)
Stopper Bolt
ASSEMBLE SST SST 0923001010, 0923114010 Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension: 8.4 mm (0.331 in)
Punch Assembly
Overhaul Handle
CO1206
5. (a)
5 1 6 4 8 3 7 2
CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 0923001010
SST Stopper Bolt
Tank Lock Plate
Z18947
(2) (3) (3) (3) (1) (1) (2) (2) (2) (2) (2) (2)
S05241
HINT:
z
Do not stake the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here (A/T) cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
Z18946
Author :
Date :
1595
CO22
(b)
S04700
Check the lock plate height (H) after completing the caulking. Plate height: 7.40 7.80 mm (0.2913 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL ECT SWITCH (a) Install a new Oring to the ECT switch. (b) Install the ECT switch. 7. INSTALL DRAIN PLUG (a) Install a new Oring to the drain plug. (b) Install the drain plug.
8. (a)
SST
(b) (c)
INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 0923001010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water.
S04704
Tank
Lock Plate ORing

S01713
(d) Inspect for leaks. HINT: On radiators with resin tanks, there is a 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.
Author :
Date :
1596
CO23
CO06M03
INSTALLATION
1. (a) (b) (c) (d) INSTALL NO.1 ELECTRIC COOLING FAN TO RADIATOR Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Connect the ECT switch connector for the cooling fan. Install the ECT switch wire clamp for the cooling fan to the bracket of the radiator. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf) INSTALL NO.2 ELECTRIC COOLING FAN TO RADIATOR Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf) INSTALL RADIATOR ASSEMBLY Install the lower radiator hose to the radiator. A/T: Install the 2 oil cooler hoses to the radiator. Install the 2 lower radiator supports to the radiator. Attach the 2 lower radiator supports on the radiator to the body brackets.
2. (a) (b) 3. (a) (b) (c) (d)
(e) (f) (g) (h) (i) (j) (k) (l) 4. 5.
S05955
Install the 2 upper radiator supports with the 2 bolts. Torque: 12.8 Nm (130 kgfcm, 9 ftlbf) Connect the upper radiator hose to the radiator. Connect the lower radiator hose to the water inlet. Connect the radiator reservoir hose to the radiator. A/T: Connect the 2 oil cooler hoses to the oil cooler pipes. Connect the No.1 electric cooling fan connector. Connect the No.2 electric cooling fan connector. Connect the ECT switch connector for the electric cooling fan. FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS
Author :
Date :
1597
CO24
COOLING (5SFE) ELECTRIC COOLING FAN
ELECTRIC COOLING FAN

CO06N03
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83C (181F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch. (c) Disconnect the ECT switch connector. (d) Check that the cooling fan rotates. If not, check the fan main relay, cooling fan relay, cooling fan, fuses, and check for short circuit between the cooling fan relay and ECT switch. (e) Reconnect the ECT switch connector. 2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93C (199F)) (a) Start the engine, and raise coolant temperature to above 93C (199F). (b) Check that the cooling fan rotates. If not, replace the ECT switch. 1.
S05959
ECT Switch Connector

S05953
No.1
Ammeter
(+) ()
3. (a) (b) (c)
(d)
INSPECT COOLING FANS Disconnect the cooling fan connector. Connect battery and ammeter to the connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 4.9 8.5 A Reconnect the cooling fan connector.
No.2
Battery () Ammeter (+)
Battery
Z19282
Author :
Date :
1598
CO25
CO06O03
COMPONENTS
No.1 Cooling Fan No.1 Electric Cooling Fan Connector
No.1 Electric Cooling Fan Upper Radiator Hose
Connector Holder
ECT Switch Connector ECT Switch Wire
S05950
No.1 Cooling Fan
Fan Motor
Fan
Connector Holder
Fan Shroud
S05238
Author :
Date :
1599
CO26
No.2 Cooling Fan
No.2 Electric Cooling Fan Connector No.2 Electric Cooling Fan
S05949
No.2 Cooling Fan Connector Holder
Fan Fan Motor Cover Fan Motor
Fan Shroud
S05239
Author :
Date :
1600
CO27
CO06P03
REMOVAL
1. (a) (b) REMOVE NO.1 COOLING FAN Drain the engine coolant. Disconnect the upper radiator hose from the radiator.
(c)
Remove the No.1 cooling fan. (1) Disconnect the cooling fan connector. (2) Disconnect the ECT switch connector. (3) Remove the 2 bolts, and disconnect the cooling fan from the radiator. (4) Disconnect the connector holder and wire for the ECT switch from the fan shroud, and remove the cooling fan.
S05956
2. (a) (b)
REMOVE NO.2 COOLING FAN Disconnect the cooling fan connector. Remove the 2 bolts and cooling fan.
S05957
Author :
Date :
1601
CO28
CO06Q03
DISASSEMBLY
1. REMOVE FAN Remove the nut and fan. 2. No.2 Cooling Fan: REMOVE FAN MOTOR COVER Remove the 2 screws and motor cover. 3. REMOVE FAN MOTOR (a) Disconnect the wire and connector holder from the fan shroud. (b) Remove the 3 screws and fan motor.
S05234
Author :
Date :
1602
CO29
CO06R04
No.1 Cooling Fan
REASSEMBLY
1. (a) (b) 2. INSTALL FAN MOTOR Install the fan motor with the 3 screws. Install the wire and connector holder to the fan shroud. No.2 Cooling Fan: INSTALL FAN MOTOR COVER Install the motor cover with the 2 screws. 3. INSTALL FAN Install the fan with the nut.
No.2 Cooling Fan
Z19069
Author :
Date :
1603
CO30
CO06S03
INSTALLATION
1. (a) INSTALL NO.1 COOLING FAN Install the No.1 cooling fan. (1) Attach the lower side of the cooling fan to the bracket of the radiator. (2) Install the cooling fan with the 2 bolts. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf) (3) Install the wire and connector holder for the ECT switch to the fan shroud. (4) Connect the cooling fan connector. (5) Connect the ECT switch connector. Connect the upper radiator hose to the radiator Fill with engine coolant Start the engine and check for coolant leaks
Attach
S06016
(b) (c) (d)
2. (a) (b) (c)
INSTALL NO.2 COOLING FAN Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf) Connect the cooling fan connector.
Attach
S06017
Author :
Date :
1604
CO31
COOLING (5SFE) ENGINE COOLANT TEMPERATURE (ECT) SWITCH
ENGINE COOLANT TEMPERATURE (ECT) SWITCH

CO06T03
INSPECTION
1. DRAIN ENGINE COOLANT
ECT Switch Connector ECT Switch
2. (a) (b) (c)
REMOVE ECT SWITCH Disconnect the connector. Remove the ECT switch. Remove the Oring from the ECT switch.
ORing
S05245
Ohmmeter
P05962
INSPECT ECT SWITCH Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 93C (199F). If there is continuity, replace the switch. (b) Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is below 83C (181F). If there is no continuity, replace the switch. 4. REINSTALL ECT SWITCH (a) Install a new Oring to the ECT switch. (b) Install the ECT switch. (c) Connect the connector. 5. REFILL WITH ENGINE COOLANT 6. START ENGINE AND CHECK FOR COOLANT LEAKS
3. (a)
Author :
Date :
1605
CO32
COOLING (5SFE) ENGINE MAIN RELAY
ENGINE MAIN RELAY

CO06U03
INSPECTION
Engine Main Relay
1. 2.
REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE MAIN)
S05391
Ohmmeter Continuity 2 Ohmmeter 5
Ohmmeter
1 3
4 Continuity
No Continuity
B02803
INSPECT ENGINE MAIN RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay.
3. (a)
Ohmmeter No Continuity 2
Ohmmeter
5 4 Battery
Continuity
B02804
Inspect the relay operation. (1) Apply battery positive voltage across terminals 3 and 5. (2) Using an ohmmeter, check that there is no continuity between terminals 2 and 4. If there is continuity, replace the relay. (3) Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 4. REINSTALL ENGINE MAIN RELAY 5. REINSTALL RELAY BOX COVER
(b)
Author :
Date :
1606
CO33
COOLING (5SFE) COOLING FAN RELAY
COOLING FAN RELAY

CO06V03
INSPECTION
No.1 Cooling Fan Relay
1. (a) (b)
INSPECT NO.1 COOLING FAN RELAY Remove the relay box cover. Remove the No.1 cooling fan relay. (Marking: FAN NO.1)
S05390
Ohmmeter 1
Ohmmeter
Continuity 3 2
Inspect the No.1 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay.
(c)
Continuity
B02801
Ohmmeter 1
(d)
No Continuity 3 2 4
Battery
Inspect the No.1 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (e) Reinstall the No.1 cooling fan relay (f) Reinstall the relay box cover.
B02802
2. (a) (b)
S05387
Ohmmeter 4 1 Ohmmeter
Continuity 2 Ohmmeter 5
3 Continuity No Continuity
S04972
Inspect the No.2 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
(c)
CO34
COOLING (5SFE) COOLING FAN RELAY
4 Battery Ohmmeter 1
2 Ohmmeter 5
3 No Continuity Continuity
S04971
Inspect the No.2 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4 If there is continuity, replace the relay. (3) Check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (e) Reinstall the No.2 cooling fan relay. (f) Reinstall the relay box cover.
(d)
3. (a) (b)
S05388
Continuity Ohmmeter 1 2 5 Ohmmeter
(c)
3 No Continuity
S04970
Inspect the No.3 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
2 1 5
Ohmmeter
3 Battery Continuity
S04969
Inspect the No.3 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (e) Reinstall the No.3 cooling fan relay. (f) Reinstall the relay box cover.
(d)
Author :
Date :
1608
CO1
COOLING (1MZFE) COOLANT
COOLANT
CO03B04
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the LOW and FULL lines, when the engine is cold. If low, check for leaks and add Toyota Long Life Coolant or Equivalent up to the FULL line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. (c) Reinstall the radiator cap.
Author :
Date :
1609
CO2
COOLING (1MZFE) COOLANT
CO03C04
REPLACEMENT
1. DRAIN ENGINE COOLANT (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
(b)
Drain Plug
Drain Plug
Z18835
Loosen the radiator drain plug and engine drain plugs, and drain the coolant. (c) Close the drain plugs. Torque: RH engine drain plug on EGR cooler: 7 Nm (70 kgfcm, 61 in.lbf) LH engine drain plug on union: 13 Nm (130 kgfcm, 9 ftlbf) 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant. z Use of improper coolants may damage engine cooling system. z Use Toyota Long life Coolant or equivalent and mix it with plan water according to the manufacturers directions. z Using of coolant which includes more than 50 % (freezing protection down to 35C (31F) or 60 % (freezing protection down to 50C (58F)) of ethyleneglycol is recommended but not more than 70 %. NOTICE: z Do not use an alcohol type coolant or plain water alone. z The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts) (b) Install the radiator cap. (c) Start the engine, and bleed the cooling system. (d) If necessary, refill coolant into the reservoir up to the FULL line. 3. CHECK ENGINE COOLANT FOR LEAKS 4. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY
Author :
Date :
1610
CO3
COOLING (1MZFE) WATER PUMP
WATER PUMP
CO03D04
COMPONENTS
RH Fender Apron Seal
64 (650, 47)
32 (320, 23)
Generator Drive Belt
Engine Moving Control Rod
64 (650, 47)
RH Engine Mounting Stay No.2 RH Engine Mounting Bracket
PS Pump Drive Belt
No.2 RH Engine Mounting Stay (M/T)
Ground Strap
Engine Coolant Reservoir Hose
Nm (kgfcm, ftlbf) : Specified torque
A06654
Author :
Date :
1611
CO4
Timing Belt Gasket
No.2 Timing Belt Cover
RH Engine Mounting Bracket

28 (290, 21)
Timing Belt Guide No.2 Generator Bracket
No.1 Timing Belt Cover Crankshaft Pulley Gasket
215 (2,200, 159)
Engine Wire Protector
No.2 Idler Pulley RH Camshaft Timing Pulley

125 (1,300, 94) *88 (900, 65) 43 (440, 32)
LH Camshaft Timing Pulley

125 (1,300, 94)
Dust Boot Timing Belt Tensioner
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part *For use with SST
27 (280, 20)
B06388
Author :
Date :
1612
CO5
Gasket No.3 Timing Belt Cover
Collar Bushing
x6
8.5 (85, 74 in.lbf)
Engine Wire
z Gasket Water Pump

8 (80, 69 in.lbf)
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part
B04403
Author :
Date :
1613
CO6
CO03E03
REMOVAL
1. 2. 3. 4. 5. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM15) REMOVE CAMSHAFT TIMING PULLEYS (See page EM15) REMOVE NO.2 IDLER PULLEY (See page EM15) REMOVE NO.3 TIMING BELT COVER (See page EM32)
6. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket.
P12942
Author :
Date :
1614
CO7
CO03F03
INSPECTION
1. INSPECT WATER PUMP (a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT TIMING BELT COMPONENTS (See page EM19)
P12487
Author :
Date :
1615
CO8
CO0SO01
INSTALLATION
1. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 Nm (80 kgfcm, 69 in.lbf) NOTICE: Do not get oil on the gasket. 2. INSTALL NO.3 TIMING BELT COVER (See page EM57) 3. INSTALL NO.2 IDLER PULLEY (See page EM21) 4. INSTALL CAMSHAFT TIMING PULLEYS (See page EM21) 5. INSTALL TIMING BELT (See page EM21) 6. FILL WITH ENGINE COOLANT 7. START ENGINE AND CHECK FOR LEAKS 8. RECHECK ENGINE COOLANT LEVEL
P12942
Author :
Date :
1616
CO9
COOLING (1MZFE) THERMOSTAT
THERMOSTAT
CO03H03
COMPONENTS
MAF Meter Connector EGR Vacuum Hose EVAP Hose
Air Cleaner Cap Assembly No.2 ECT Switch Connector
Air Filter Engine Wire Protector
Thermostat z Gasket Water Inlet z ORing Water Inlet Pipe

8 (80, 69 in.lbf)
19.5 (200, 14)
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part
B06397
Author :
Date :
1617
CO10
CO03I03
REMOVAL
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR FILTER 3. DISCONNECT NO.2 ECT SWITCH CONNECTOR 4. DISCONNECT ENGINE WIRE PROTECTOR FROM WATER INLET AND RH CYLINDER HEAD Remove the 2 nuts, and disconnect the engine wire protector from the water inlet and cylinder head.
S04581
5. (a) (b)
DISCONNECT WATER INLET PIPE FROM WATER INLET AND LH CYLINDER HEAD Remove the bolt, and disconnect the inlet pipe from the water inlet. Remove the Oring from the inlet pipe.
S04502
6. (a) (b)
REMOVE WATER INLET AND THERMOSTAT Remove the 3 nuts, water inlet and thermostat. Remove the gasket from the thermostat.
S04503
Author :
Date :
1618
CO11
CO03J03
INSPECTION
INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature.
P13255
Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 84C (176 183F) If the valve opening temperature is not as specified, replace the thermostat.
(a)
CO0601
Check the valve lift. Valve lift: 10.0 mm (0.394 in.) or more at 95C (203F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40C (104F)). If not closed, replace the thermostat.
10 mm
Z10579
(c)
Author :
Date :
1619
CO12
CO03K03
INSTALLATION
1. (a) PLACE THERMOSTAT IN WATER PUMP Install a new gasket on to the thermostat.
(b)
Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
15 15
Jiggle Valve Stud Bolt

S04532
HINT: The jiggle valve may be set within 15 of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 8 Nm (80 kgfcm, 69 in.lbf) 3. INSTALL WATER INLET PIPE (a) Install a new Oring to the water inlet pipe. (b) Apply soapy water to the Oring. (c) Connect the water inlet pipe to the water inlet. (d) Install the bolt holding the water inlet pipe to the cylinder head. Torque: 19.5 Nm (200 kgfcm, 14 ftlbf) 4. INSTALL ENGINE WIRE PROTECTOR 5. CONNECT NO.2 ECT SWITCH CONNECTOR 6. REINSTALL AIR FILTER AND AIR CLEANER CAP ASSEMBLY 7. FILL WITH ENGINE COOLANT 8. START ENGINE AND CHECK FOR LEAKS 9. RECHECK ENGINE COOLANT LEVEL
Author :
Date :
1620
CO13
COOLING (1MZFE) RADIATOR
RADIATOR
CO03L03
ONVEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core)
Author :
Date :
1621
CO14
CO03M03
1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blow out under pressure. 2. INSPECT RADIATOR CAP NOTICE: z If the radiator cap has contaminations, always rinse it with water. z When performing steps (a) and (b) below, keep the radiator cap tester at an angle of over 30 above the horizontal. z Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
Radiator Cap Tester
30 or More Radiator Cap

Z00570
Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 83 113 kPa (0.85 1.15 kgf/cm2, 12.1 16.4 psi) Minimum opening pressure: 69 kPa (0.7 kgf/cm2, 10.0 psi) HINT: Use the testers maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap.
(a)
Author :
Date :
1622
CO15
Radiator Cap Tester
P13014
INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 127 kPa (1.3 kgf/cm2, 18.5 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. 4. REINSTALL RADIATOR CAP
3. (a)
Author :
Date :
1623
CO16
CO03N03
COMPONENTS
A/T Oil Cooler Hose Radiator No.2 Cooling Fan
No.1 Cooling Fan z ORing No.1 ECT Switch No.2 Cooling Fan Connector Upper Radiator Support No.1 ECT Switch Wire Upper Radiator Hose Upper Radiator Support No.1 Cooling Fan Connector Radiator Assembly Lower Radiator Hose
Lower Radiator Support Drain Plug z ORing Lower Radiator Support
No.1 ECT Switch Wire Connector
Relay Block (for Daytime Running Light System)
Lower Radiator Hose A/T Oil Cooler Hose
z Nonreusable part
B06399
Author :
Date :
1624
CO17
Upper Tank
z ORing A/T
Oil Cooler Cushion Core
Inlet Pipe
z ORing
Plate Washer Nut
Lower Tank
z ORing
z Nonreusable part
S04606
Author :
Date :
1625
CO18
CO03O03
REMOVAL
HINT:
z z z
1. 2.
3. 4. 5. 6. 7.
At the time of installation, please refer to the following items. Start the engine, and check for coolant and A/T fluid leaks. Check the A/T fluid level. (See page DI438) DRAIN ENGINE COOLANT CANADA: DISCONNECT RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) FROM BATTERY HOLDDOWN CLAMP DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR DISCONNECT LOWER RADIATOR HOSE FROM WATER INLET PIPE DISCONNECT A/T OIL COOLER HOSES FROM OIL COOLER PIPES DISCONNECT NO.1 AND NO.2 COOLING FAN CONNECTORS DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR
8. (a) (b) (c)

S04725
REMOVE RADIATOR AND COOLING FANS ASSEMBLY Remove the 2 bolts and 2 upper supports. Torque: 12.8 Nm (130 kgfcm, 9 ftlbf) Lift out the radiator, and remove the radiator and cooling fans assembly. Remove the 2 lower supports.
Lower Hose
9. 10.
REMOVE A/T OIL COOLER HOSES FROM RADIATOR REMOVE LOWER RADIATOR HOSE FROM RADIATOR
Oil Cooler Hose

B05937
Author :
Date :
1626
CO19
11.
REMOVE NO.1 ECT SWITCH
S04588
No.1
No.2
12. REMOVE NO.1 COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf) 13. REMOVE NO.2 COOLING FAN FROM RADIATOR Remove the 3 bolts and cooling fan. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf)
B05938
Author :
Date :
1627
CO20
CO03P03
Part A
DISASSEMBLY
1. 2. REMOVE CUSHION FROM RADIATOR ASSEMBLE SST SST 0923001010 (a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension B shown in the diagram is 0.2 0.5 mm (0.008 0.020 in.). NOTICE: If this adjustment is not done, the claw may be damaged.
Dimension B
SST Stopper Bolt
Claw
Overhaul Handle
CO1205
Tank
Lock Plate SST
3. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 0923001010
Stopper Bolt
S04737
4. (a)
Tap
(b)
REMOVE TANKS AND ORINGS Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a softfaced hammer and remove the tank. Remove the Oring.
S04738
A/T
5. (a) (b) (c)
A/T: REMOVE OIL COOLER FROM LOWER TANK Remove the pipe. Remove the nuts and plate washers. Remove the oil cooler and Orings.
Z18546
Author :
Date :
1628
CO21
CO03Q03
A/T (2)
(1) (6)
REASSEMBLY
1. (a)
(5) (4)
Z18506
(3)
(b) (c) (d)
(e)
A/T: INSTALL OIL COOLER TO LOWER TANK Clean the Oring contact surface of the lower tank and oil cooler. Install a new Orings (1) to the oil cooler (2). Install the oil cooler with the Orings to the lower tank (3). Install the plate washers (4), and nuts (5). Torque the nuts. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) Install the pipe (6). Torque: 14.7 Nm (150 kgfcm, 11 ftlbf)
Lock Plate
Lock Plate
Core
CO1267
2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: z If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. z Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented, Therefore, repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
3. (a)
f Normal X Twisted
INSTALL NEW ORINGS AND TANKS After checking that there are no foreign objects in the lock plate groove, install the new Oring without twisting it.
HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
ORing
X Twisted
CO0317
Author :
Date :
1629
CO22
CORRECT Tank WRONG Lock Plate

S04736
(b) (c)
Install the tank without damaging the Oring. Tap the lock plate with a softfaced hammer so that there is no gap between it and the tank.
Tap
4.
Part A
(a)
Dimension B
SST
(b)
Stopper Bolt
ASSEMBLE SST SST 0923001010, 0923114010 Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B shown in the diagram. Dimension B: 8.4 mm (0.34 in.)
Punch Assembly
Overhaul Handle CO1206
5 1 6
5. (a)
7 2
4 SST
CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 0923001010
St opper Bolt Tank Lock Plate
S04739
Rib
HINT:
z
Do not stake the areas protruding around the pipes, brackets or tank ribs.
Bracket
S04734
Author :
Date :
1630
CO23
The points shown in the rib sides and oil cooler near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates.
S04726
(b)
Check the lock plate height (H) after completing the caulking. Plate height (H): 7.4 7.8 mm (0.2959 0.3119 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL CUSHION
H
S04735
Author :
Date :
1631
CO24
CO03R01
INSTALLATION
Installation is in the reverse order of removal. (See page CO18)
Author :
Date :
1632
CO25
COOLING (1MZFE) ELECTRIC COOLING FAN
ELECTRIC COOLING FAN

CO03S03
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 88C (190F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch. (c) Disconnect the No.1 ECT switch connector. 1.
B05939
Disconnect
S04727
(d) Check that the cooling fan rotates. If not, check the fuses, engine main relay, cooling fan relay, cooling fan, and check for a short circuit between the cooling fan relay and ECT switch. (e) Reconnect the No.1 ECT switch connector.
B05940
CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 98C (208F)) (a) Start the engine, and raise coolant temperature to above 98C (208F). (b) Check that the cooling fan rotates. If not, replace the No.1 ECT switch.
2.
Ammeter
3. (a) (b) (c)
(d)
Battery
B05941
INSPECT NO.1 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.3 11.3 A at 20C (68F) Reconnect the cooling fan connector.
Author :
Date :
1633
CO26
Ammeter
4. (a) (b) (c)
(d)
Battery B05942
INSPECT NO.2 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.3 11.3 A at 20C (68F) Reconnect the cooling fan connector.
Author :
Date :
1634
CO27
CO03T03
COMPONENTS
No.1
Fan
Fan Motor
z Clip Fan Shroud No.1 Cooling Fan Connector
No.1 Cooling Fan No.1 ECT Switch Connector No.1 ECT Switch Wire
Relay Block (for Daytime Running Light System)
z Nonreusable part
B06400
Author :
Date :
1635
CO28
No.2
Fan
Fan Motor
z Clip
Fan Shroud
No.2 Cooling Fan Connector
No.2 Cooling Fan
Upper Radiator Hose
z Nonreusable part
B06402
Author :
Date :
1636
CO29
CO03U03
REMOVAL
1. (a) REMOVE NO.1 COOLING FAN Canada: Disconnect the relay block (for daytime running light system) from the battery holddown clamp. Disconnect the cooling fan connector. Disconnect the No.1 ECT switch wire connector. Disconnect the No.1 ECT switch wire clamps.
(b) (c) (d)
(e)
Remove the 2 bolts and cooling fan. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf)
B05943
2. (a) (b) (c)
REMOVE NO.2 COOLING FAN Drain the engine coolant. Disconnect the upper radiator hose from the radiator. Disconnect the cooling fan connector.
(d)
Remove the 3 bolts and cooling fan. Torque: 5.0 Nm (50 kgfcm, 44 in.lbf)
B05944
Author :
Date :
1637
CO30
CO03V03
Protrusion
DISASSEMBLY
1. REMOVE NO.1 COOLING FAN (a) Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: At the time of installation, please refer to the following items. Install a new clip from the side opposite the protrusion on the fan.
B05945
(b)
Disconnect the lead wire from the fan shroud.
S04584
(c)
Remove the 3 screws and fan motor.
S04587
Protrusion
B05946
2. REMOVE NO.2 COOLING FAN (a) Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: At the time of installation, please refer to the following items. Install a new clip from the side opposite the protrusion on the fan.
CO31
(b)
Disconnect the lead wire from the fan shroud.
S04585
(c)
Remove the 3 screws and fan motor.
S04586
Author :
Date :
1639
CO32
CO03W01
REASSEMBLY
Reassembly is in the reverse order of disassembly. (See page CO30)
Author :
Date :
1640
CO33
CO03X01
INSTALLATION
Installation is in the reverse order of removal. (See page CO29)
Author :
Date :
1641
CO34
COOLING (1MZFE) ENGINE COOLANT TEMPERATURE (ECT) SWITCH
ENGINE COOLANT TEMPERATURE (ECT) SWITCH

CO03Y04
INSPECTION
1. DRAIN ENGINE COOLANT
2. (a)
INSPECT NO.1 ECT SWITCH Remove the No.1 ECT switch.
No.1 ECT Switch

S04602
Ohmmeter
P01924
Inspect the No.1 ECT switch. (1) Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 98C (208F). If there is continuity, replace the switch. (2) Check that there is continuity, between the terminals when the coolant temperature is below 88C (190F). If there is no continuity, replace the switch. (c) Reinstall the No.1 ECT switch. 3. INSPECT NO.2 ECT SWITCH (a) Remove the No.2 ECT switch.
(b)
No.2 ECT Switch
S04601
Ohmmeter
P06722
Inspect the No.2 ECT switch. (1) Using an ohmmeter, check that there is continuity between terminals when the coolant temperature is above 94C (201F). If there is no continuity, replace the switch. (2) Check that there is no continuity between the terminals when the coolant temperature is below 83C (181F). If there is continuity, replace the switch. (c) Reinstall the No.2 ECT switch.
(b)
CO35
COOLING (1MZFE) ENGINE COOLANT TEMPERATURE (ECT) SWITCH
4. 5.
REFILL ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS
Author :
Date :
1643
CO36
COOLING (1MZFE) ENGINE MAIN RELAY
ENGINE MAIN RELAY

CO03Z03
INSPECTION
Engine Main Relay
1. 2.
REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE MAIN)
S05391
Ohmmeter Continuity 2 1 Ohmmeter
3. (a)
Ohmmeter
5 4 Continuity 3 No Continuity
S04974
INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 4. (a) (b) INSPECT RELAY OPERATION Apply battery positive voltage across terminals 3 and 5. Using an ohmmeter, check that there is no continuity between terminals 2 and 4. If there is continuity, replace the relay. (c) Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 5. REINSTALL ENGINE MAIN RELAY 6. REINSTALL RELAY BOX COVER
Ohmmeter No Continuity 2 1
Ohmmeter
5 4 Battery 3 Continuity
S04973
Author :
Date :
1644
CO37
COOLING (1MZFE) COOLING FAN RELAY
COOLING FAN RELAY

CO04003
INSPECTION
1. 2. (a)
REMOVE RELAY BOX COVER INSPECT NO.1 COOLING FAN RELAY Remove the No.1 cooling fan relay. (Marking: FAN NO.1)
S05390
Ohmmeter Continuity 1 4 3 2
Continuity
Ohmmeter
Inspect the No.1 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay.
(b)
S04975
Ohmmeter No Continuity 1 4 3 2 Battery

S04976
(c)
Inspect the No.1 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (d) Reinstall the No.1 cooling fan relay.
3. (a)
INSPECT NO.2 COOLING FAN RELAY Remove the No.2 cooling fan relay. (Marking: FAN NO.2)
S05387
Ohmmeter 4 1 Ohmmeter 3 Continuity No Continuity

S04972
2 5
Ohmmeter
Inspect the No.2 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
(b)
CO38
COOLING (1MZFE) COOLING FAN RELAY
(c)
4 1 2 Ohmmeter 5
Battery Ohmmeter
3 No Continuity Continuity
S04971
Inspect the No.2 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (d) Reinstall the No.2 cooling fan relay.
4. (a)
INSPECT NO.3 COOLING FAN RELAY Remove the No.3 cooling fan relay. (Marking: FAN NO.3)
S05388
Continuity Ohmmeter 1 2 5 Ohmmeter
3 No Continuity
S04970
Inspect the No.3 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is mo continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.
(b)
(c)
2 1 5 Ohmmeter
3 Battery Continuity
S04969
Inspect the No.3 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (d) Reinstall the No.3 cooling fan relay. 5. REINSTALL RELAY BOX COVER
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CO1

COOLING (5SFE) COOLANT

Radiator Drain Plug

Engine Drain Plug

(b) (c) (d) 3.

64 (650, 47) 64 (650, 47)

Engine Moving Control Rod

Cylinder Block Insulator

PS Pump Drive Belt

RH Front Fender Apron Seal

Nm (kgfcm, ftlbf) : Specified torque

Wire Clamp z ORing Wire Clamp No.1 Idler Pulley

Tension Spring z ORing No.2 Idler Pulley z Gasket

Generator Drive Belt Adjusting Bar Wire Clamp

7. (a) (b) (c)

Remove the 3 bolts in the sequence shown.

2. (a) (b) (c) (d)

3. (a) (b) (c) 4.

Thermostat z Gasket Water Inlet

3. (a) (b) (c)

Radiator Cap Tester

30 or More Radiator Cap

Radiator Cap Tester

Lower Radiator Support

Lower Radiator Hose Upper Radiator Hose

Oil Cooler Hose for A/T

Lower Radiator Hose

ECT Switch Connector for Electric Cooling Fan

No.2 Electric Cooling Fan

Wire Clamp Radiator

No.1 Electric Cooling Fan

Oil Cooler Hose for A/T

(h) (i) (j) (k) (l)

Overhaul Handle Tank

6. (a) (b) (c)

SST Stopper Bolt

Tank Lock Plate

Lock Plate ORing

2. (a) (b) 3. (a) (b) (c) (d)

(e) (f) (g) (h) (i) (j) (k) (l) 4. 5.

ELECTRIC COOLING FAN

ECT Switch Connector

3. (a) (b) (c)

Battery () Ammeter (+)

No.1 Electric Cooling Fan Upper Radiator Hose

ECT Switch Connector ECT Switch Wire

No.1 Cooling Fan

No.2 Cooling Fan

No.2 Electric Cooling Fan Connector No.2 Electric Cooling Fan

No.2 Cooling Fan Connector Holder

Fan Fan Motor Cover Fan Motor

No.1 Cooling Fan

No.2 Cooling Fan

(b) (c) (d)

2. (a) (b) (c)

ENGINE COOLANT TEMPERATURE (ECT) SWITCH

ECT Switch Connector ECT Switch

2. (a) (b) (c)

ENGINE MAIN RELAY

Ohmmeter Continuity 2 Ohmmeter 5

COOLING FAN RELAY

No.2 Cooling Fan Relay

No.3 Cooling Fan Relay