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CO–1

COOLING (5S–FE) – COOLANT

COOLANT
CO066–03

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

CO–2
COOLING (5S–FE) – COOLANT
CO067–03

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 N·m (250 kgf·cm, 18 ft·lbf) 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 manufacturer’s directions. z Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 % (freezing protection down to –50°C (–58°F)) of ethylene–glycol 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

CO–3
COOLING (5S–FE) – WATER PUMP

WATER PUMP
CO068–03

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

N·m (kgf·cm, ft·lbf) : Specified torque

S05543

Author :

Date :

1577

13) Wire Clamp 108 (1.1 Timing Belt Cover Crankshaft Pulley * Gasket Wire Clamp Timing Belt Timing Belt Guide High–Tension Cord Spark Plug 18 (180.1 Idler Pulley 42 (425.100.31) Tension Spring z O–Ring No.2 Idler Pulley z Gasket 42 (425.CO–4 COOLING (5S–FE) – WATER PUMP Generator Wire * Gasket Generator Connector Generator Wire Clamp No.2 Timing Belt Cover No. ft·lbf) : Specified torque * Replace only if damaged z Non–reusable part S05939 Author : Date : 1578 .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 N·m (kgf·cm. 80) Wire Clamp z O–Ring Wire Clamp No.

(a) (b) (c) REMOVE GENERATOR DRIVE BELT ADJUSTING BAR Disconnect the engine wire clamp from the adjusting bar. REMOVE TIMING BELT TENSION SPRING Loosen the No.CO–5 COOLING (5S–FE) – WATER PUMP CO069–04 REMOVAL 1. (a) REMOVE WATER PUMP AND WATER PUMP COVER ASSEMBLY Remove the 2 nuts holding the water pump to the water bypass pipe. 2 S05963 Author : Date : 1579 . DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–17) DISCONNECT LOWER RADIATOR HOSE FROM WATER OUTLET 4.1 idler pulley bolt. S05924 (b) 1 3 Remove the 3 bolts in the sequence shown. 2.2 IDLER PULLEY Remove the bolt and idler pulley. Disconnect the crankshaft position sensor connector from the bracket on the adjusting bar. w/ Oil Cooler: REMOVE A/C COMPRESSOR (See page EM–69) 7. Remove the bolt and adjusting bar. 6. 3. 5. REMOVE NO. and remove the tension spring. S05599 8.

CO–6 COOLING (5S–FE) – WATER PUMP Disconnect (c) Disconnect the water pump cover from the water bypass pipe. (d) Remove the gasket and 2 O–rings from the water pump and water bypass pipe. S05965 Author : Date : 1580 . water pump and gasket. and remove the water pump and water pump cover assembly. REMOVE WATER PUMP FROM WATER PUMP COVER Remove the 3 bolts. 9.

(b) Turn the pulley. If engine coolant has leaked onto the timing belt. replace the water pump.CO–7 COOLING (5S–FE) – WATER PUMP CO06A–03 Turn INSPECTION 1. INSPECT WATER PUMP (a) Visually check the air hole for coolant leakage. INSPECT TIMING BELT COMPONENTS (See page EM–22) Air Hole S01486 Author : Date : 1581 . replace the timing belt. 2. If necessary. replace the water pump. If leakage is found. and check that the water pump bearing moves smoothly and quietly.

·lbf) N00918 Connect 2. Torque: 8.CO–8 COOLING (5S–FE) – WATER PUMP CO06B–03 INSTALLATION 1. Torque: 8. 78 in. (a) (b) (c) (d) S06015 INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY Install new O–ring and gasket to water pump cover.3 N·m (95 kgf·cm. Do not install the nuts yet. Tighten the bolts in the sequence shown. Torque: 22 N·m (224 kgf·cm.2 IDLER PULLEY (See page EM–23) Author : Date : 1582 .8 N·m (90 kgf·cm. S05599 5. w/ Oil Cooler: INSTALL A/C COMPRESSOR (See page EM–75) INSTALL NO. Install the crankshaft position sensor connector to the bracket on the adjusting bar. Install a new O–ring to the water bypass pipe. 82 in. INSTALL WATER PUMP TO WATER PUMP COVER Install a new gasket and the water pump with the 3 bolts. Connect the water pump cover to the water bypass pipe.·lbf) S05924 3.8 N·m (90 kgf·cm. 16 ft·lbf) Install the engine wire clamp to the adjusting bar. Apply soapy water to the O–ring on the water bypass pipe. (a) (b) (c) 4. Torque: 9. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR Install the adjusting bar with the bolt. (e) 3 1 Install the water pump with the 3 bolts. 78 in.·lbf) 2 Z19283 (f) Install the 2 nuts holding the water pump cover to the water bypass pipe.

CO–9 COOLING (5S–FE) – WATER PUMP 6. 10. 9. 8. INSTALL TIMING BELT TENSION SPRING (See page EM–23) CONNECT LOWER RADIATOR HOSE TO WATER INLET INSTALL TIMING BELT (See page EM–23) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author : Date : 1583 . 7.

CO–10 COOLING (5S–FE) – THERMOSTAT THERMOSTAT CO06C–03 COMPONENTS w/ Oil Cooler Oil Filter Thermostat z Gasket Water Inlet z Non–reusable part S05299 Author : Date : 1584 .

Remove the thermostat. causing a lowering of cooling efficiency. w/ Oil Cooler: REMOVE OIL FILTER (See page LU–2) 3.CO–11 COOLING (5S–FE) – THERMOSTAT CO06D–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect. Remove the gasket from the thermostat. DRAIN ENGINE COOLANT 2. S05322 Author : Date : 1585 . Do not remove the thermostat. 1. (a) (b) (c) REMOVE WATER INLET AND THERMOSTAT Remove the 2 nuts. even if the engine tends to overheat. and disconnect the water inlet from the water pump cover.

Valve lift: 8 mm (0. replace the thermostat.CO–12 COOLING (5S–FE) – THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. Valve Lift P24125 (c) Author : Date : 1586 .31 in. replace the thermostat. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified. (a) P00436 Check the valve lift. replace the thermostat. CO06E–03 P13560 Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. If not closed. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)).) or more at 95°C (203°F) If the valve lift is not as specified.

CO–13 COOLING (5S–FE) – THERMOSTAT CO0SN–01 5° 5° Protrusion INSTALLATION 1.8 N·m (90 kgf·cm. 78 in. INSTALL WATER INLET AND THERMOSTAT Install the water inlet and thermostat with the 2 nuts. FILL WITH ENGINE COOLANT 5. Torque: 8. Jiggle Valve P13611 HINT: The jiggle valve may be set within 5° of either side of the prescribed position. CHECK ENGINE OIL LEVEL S05322 Author : Date : 1587 . w/ Oil Cooler: INSTALL OIL FILTER (See page LU–2) 4. (a) (b) PLACE THERMOSTAT IN WATER INLET Install a new gasket to the thermostat. and insert the thermostat in the water inlet. START ENGINE AND CHECK FOR COOLANT LEAKS 6.·lbf) 3. 2. Align the jiggle valve of the thermostat with the protrusion of the water inlet.

) Author : Date : 1588 . (i. be careful not to deform the fins of the radiator core.e. NOTICE: If using a high pressure type cleaner.CO–14 COOLING (5S–FE) – RADIATOR RADIATOR CO06G–03 ON–VEHICLE CLEANING Using water or a steam cleaner. remove any mud or dirt from the radiator core. Maintain a distance between the cleaner nozzle and radiator core.

the pump speed can be reduced. keep the tester at an angle of over 30° above the horizontal. replace the radiator cap. 4. 3. replace the radiator cap.05 kgf/cm2.1 psi).9 psi) Minimum opening pressure: 59 kPa (0. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned. REINSTALL RADIATOR CAP Author : Date : 1589 . If the opening pressure is less than minimum.2 kgf/cm2. 8. always rinse it with water. If air is not coming from the vacuum valve. z Before using a radiator cap tester. z When performing steps (a) and (b) below. If no external leaks are found. and attach a radiator cap tester. do not remove the radiator cap while the engine and radiator are still hot.7 – 14. as fluid and steam can be blown out under pressure. cylinder block and head. slowly pump the tester and check that air is coming from the vacuum valve. If the pressure drops. After this. and check that the pressure does not drop.75 – 1. wet the relief valve and pressure valve with engine coolant or water. (a) Using a radiator cap tester. check the heater core. Standard opening pressure: 74 – 103 kPa (0. check the hoses. 17. INSPECT RADIATOR CAP NOTICE: z If the radiator cap has contaminations. and measure the relief valve opening pressure.5 psi) HINT: Use the tester’s maximum reading as the opening pressure.6 kgf/cm2. 10.CO–15 COOLING (5S–FE) – RADIATOR CO06H–04 ON–VEHICLE INSPECTION 1. (b) Warm up the engine. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator with coolant. (c) Pump it to 118 kPa (1. Radiator Cap Tester 30° or More Radiator Cap Z00570 Radiator Cap Tester B06362 2. (b) Pump the tester. radiator or water pump for leaks. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve).

CO–16 COOLING (5S–FE) – RADIATOR CO06I–03 COMPONENTS Upper 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 .2 Electric Cooling Fan Connector Radiator Assembly Radiator Reservoir Hose Upper Radiator Support Lower Radiator Support No.

1 Electric Cooling Fan Oil Cooler Hose for A/T S05948 Radiator Cap Upper Tank z O–Ring A/T z O–Ring Plate Washer Nut Pipe Oil Cooler z O–Ring z O–Ring Nut Plate Washer Core z O–Ring ECT Switch for Electric Cooling Fan Lower Tank Drain Plug z O–Ring z Non–reusable part S05240 Author : Date : 1591 .2 Electric Cooling Fan Wire Clamp Radiator No.CO–17 COOLING (5S–FE) – RADIATOR Lower Radiator Hose ECT Switch Connector for Electric Cooling Fan No.

4. (c) Remove the 2 bolts and cooling fan. Disconnect the lower radiator hose from the water inlet. Disconnect the ECT switch connector for the electric cooling fan. Remove the lower radiator hose from the radiator.CO–18 COOLING (5S–FE) – RADIATOR CO06J–04 REMOVAL 1.1 ELECTRIC COOLING FAN FROM RADIATOR (a) Disconnect the ECT switch connector for the cooling fan.1 electric cooling fan connector.2 ELECTRIC COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Disconnect the No. A/T: Remove the 2 oil cooler hoses from the radiator. REMOVE NO. Disconnect the upper radiator hose from the radiator.2 electric cooling fan connector. 3. (a) (b) (c) (d) (e) (f) (g) DRAIN ENGINE COOLANT REMOVE RADIATOR ASSEMBLY Disconnect the No. Remove the 2 lower radiator supports. REMOVE NO. A/T: Disconnect the 2 oil cooler hoses from the oil cooler pipes. 2. (b) Disconnect the ECT switch wire clamp for the cooling fan from the bracket of the radiator. (h) (i) (j) (k) (l) S05955 Remove the 2 bolts and 2 upper radiator supports. Disconnect the radiator reservoir hose from the radiator. Remove the radiator assembly. Author : Date : 1592 .

S04705 Author : Date : 1593 . Dimension ”B” SST Stopper Bolt Claw Overhaul Handle Tank CO1205 ASSEMBLE SST SST 09230–01010 (a) Install the claw to the overhaul handle. REMOVE DRAIN PLUG Remove the drain plug.3 mm (0. Dimension: 0. and remove the cooler pipe. inserting it in the hole in part ”A” as shown in the diagram. Tap S04703 6. (a) (b) REMOVE ECT SWITCH Remove the ECT switch. adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Remove the oil cooler and 2 O–rings. REMOVE TANKS AND O–RINGS Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft–faced hammer. (b) While gripping the handle.2 – 0. Remove the O–ring.012 in) NOTICE: If this adjustment is not done the claw may be damaged.CO–19 COOLING (5S–FE) – RADIATOR CO06K–03 DISASSEMBLY 1. (a) (b) 2. Remove the O–ring. squeeze the handle until stopped by the stopper bolt. UNCAULK LOCK PLATES Using SST to release the caulking. and remove the tank and the O–ring. (a) (b) (c) A/T: REMOVE OIL COOLER FROM LOWER TANK Loosen the nut. Remove the 2 nuts and plate washers. 4. Part ”A” 3. SST 09230–01010 SST Lock Plate Stopper Bolt S04699 5.008 – 0.

Install the oil cooler to the lower tank with the 2 plate washers and nuts. 3. HINT: When cleaning the lock plate groove. reassembly of the tank will be impossible.CO–20 COOLING (5S–FE) – RADIATOR CO06L–04 Pipe 18° Downward REASSEMBLY 1. INSPECT LOCK PLATE FOR DAMAGE HINT: z If the sides of the lock plate groove are deformed.3 N·m (85 kgf·cm. NOTICE: The radiator can only be recaulked 2 times. first correct any deformation with pliers or similar object. O–Ring X Twisted CO0317 CORRECT Tank (b) (c) Install the tank without damaging the O–ring. After the 2nd time. 74 in.·lbf) Install the cooler pipe in the direction indicated in the illustration. lightly rub it with sand paper without scratching it. the radiator core must be replaced. install the new O–ring without twisting it. Water leakage will result if the bottom of the lock plate groove is damaged or dented.7 N·m (150 kgf·cm. Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. 11 ft·lbf) (c) S05307 Lock Plate Lock Plate Core CO1267 f Normal X Twisted 2. Torque: 14. INSTALL NEW O–RINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove. z Therefore. (a) (b) A/T: INSTALL OIL COOLER TO LOWER TANK Install 2 new O–rings to the oil cooler. WRONG Tap Lock Plate S04698 Author : Date : 1594 . Torque: 8.

fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. (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. inserting it in the hole in part ”A” as shown in the illustration.4 mm (0.331 in) Punch Assembly Overhaul Handle CO1206 5. 09231–14010 Install the punch assembly to the overhaul handle. After repeating this a few times. Dimension: 8. SST 09230–01010 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.CO–21 COOLING (5S–FE) – RADIATOR 4. Use pliers or similar object and be careful not to damage the core plates. While gripping the handle. Part ”A” (a) Dimension ”B” SST (b) Stopper Bolt ASSEMBLE SST SST 09230–01010. Z18946 Author : Date : 1595 . adjust the stopper bolt so that dimension ”B” is as shown in the illustration. z The points shown in the illustration and oil cooler near here (A/T) cannot be staked with the SST.

first swish the radiator around in the water until all air bubbles disappear. Plate height: 7.CO–22 COOLING (5S–FE) – RADIATOR (b) H S04700 Check the lock plate height (H) after completing the caulking. Therefore. INSTALL ECT SWITCH (a) Install a new O–ring to the ECT switch. 6. S04704 Tank Lock Plate O–Ring S01713 (d) Inspect for leaks. 26 psi) Submerge the radiator in water. 8. Author : Date : 1596 .2913 – 0. (b) Install the ECT switch. before doing the water leak test. (b) Install the drain plug. SST 09230–01010 Using a radiator cap tester. there is a clearance between the tank and lock plate where a minute amount of air will remain.80 mm (0.) If not within the specified height. Test pressure: 177 kPa (1. giving the appearance of an air leak when the radiator is submerged in water.3071 in. 7.8 kgf/cm2.40 – 7. HINT: On radiators with resin tanks. INSTALL DRAIN PLUG (a) Install a new O–ring to the drain plug. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. adjust the stopper bolt of the handle again and caulk again. apply pressure to the radiator.

CO–23
COOLING (5S–FE) – RADIATOR
CO06M–03

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 N·m (50 kgf·cm, 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 N·m (50 kgf·cm, 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 N·m (130 kgf·cm, 9 ft·lbf) 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

CO–24
COOLING (5S–FE) – ELECTRIC COOLING FAN

ELECTRIC COOLING FAN
CO06N–03

ON–VEHICLE INSPECTION
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83°C (181°F)) (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 93°C (199°F)) (a) Start the engine, and raise coolant temperature to above 93°C (199°F). (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

CO–25
COOLING (5S–FE) – ELECTRIC COOLING FAN
CO06O–03

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

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 .CO–26 COOLING (5S–FE) – ELECTRIC COOLING FAN No.

(1) Disconnect the cooling fan connector. and disconnect the cooling fan from the radiator. S05957 Author : Date : 1601 .1 cooling fan. (2) Disconnect the ECT switch connector. (4) Disconnect the connector holder and wire for the ECT switch from the fan shroud. (a) (b) REMOVE NO.2 COOLING FAN Disconnect the cooling fan connector.CO–27 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06P–03 REMOVAL 1. S05956 2.1 COOLING FAN Drain the engine coolant. (3) Remove the 2 bolts. Remove the 2 bolts and cooling fan. Disconnect the upper radiator hose from the radiator. (a) (b) REMOVE NO. (c) Remove the No. and remove the cooling fan.

REMOVE FAN MOTOR (a) Disconnect the wire and connector holder from the fan shroud.2 Cooling Fan: REMOVE FAN MOTOR COVER Remove the 2 screws and motor cover. (b) Remove the 3 screws and fan motor. REMOVE FAN Remove the nut and fan. 3. 2.CO–28 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06Q–03 DISASSEMBLY 1. S05234 Author : Date : 1602 . No.

3. INSTALL FAN MOTOR Install the fan motor with the 3 screws.CO–29 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06R–04 No. INSTALL FAN Install the fan with the nut.2 Cooling Fan Z19069 Author : Date : 1603 .1 Cooling Fan REASSEMBLY 1. (a) (b) 2. No. Install the wire and connector holder to the fan shroud.2 Cooling Fan: INSTALL FAN MOTOR COVER Install the motor cover with the 2 screws. No.

Torque: 5. Attach S06017 Author : Date : 1604 . 44 in. (4) Connect the cooling fan connector. 44 in.·lbf) (3) Install the wire and connector holder for the ECT switch to the fan shroud.2 COOLING FAN Attach the lower side of the cooling fan to the bracket of the radiator.1 COOLING FAN Install the No. Install the cooling fan with the 2 bolts. (2) Install the cooling fan with the 2 bolts. 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. (1) Attach the lower side of the cooling fan to the bracket of the radiator.·lbf) Connect the cooling fan connector. (a) INSTALL NO.0 N·m (50 kgf·cm. (5) Connect the ECT switch connector.0 N·m (50 kgf·cm.CO–30 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06S–03 INSTALLATION 1. (a) (b) (c) INSTALL NO. Torque: 5.1 cooling fan.

Remove the ECT switch. If there is no continuity. Remove the O–ring from the ECT switch. O–Ring S05245 Ohmmeter P05962 INSPECT ECT SWITCH Using an ohmmeter. 5. check that there is continuity between the terminals when the coolant temperature is below 83°C (181°F). (c) Connect the connector. (a) Author : Date : 1605 . (a) (b) (c) REMOVE ECT SWITCH Disconnect the connector. (b) Using an ohmmeter. replace the switch. replace the switch. (b) Install the ECT switch. REFILL WITH ENGINE COOLANT 6. DRAIN ENGINE COOLANT ECT Switch Connector ECT Switch 2. If there is continuity.CO–31 COOLING (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO06T–03 INSPECTION 1. 4. START ENGINE AND CHECK FOR COOLANT LEAKS 3. REINSTALL ECT SWITCH (a) Install a new O–ring to the ECT switch. check that there is no continuity between the terminals when the coolant temperature is above 93°C (199°F).

If there is no continuity. (2) Using an ohmmeter. REINSTALL ENGINE MAIN RELAY 5. If there is continuity. (3) Check that there is continuity between terminals 1 and 2. (1) Using an ohmmeter. If there is continuity. replace the relay. 4. (3) Check that there is no continuity between terminals 1 and 2. replace the relay.CO–32 COOLING (5S–FE) – ENGINE MAIN RELAY ENGINE MAIN RELAY CO06U–03 INSPECTION Engine Main Relay 1. (2) Check that there is continuity between terminals 2 and 4. (1) Apply battery positive voltage across terminals 3 and 5. 3. replace the relay. 2. REINSTALL RELAY BOX COVER (b) Author : Date : 1606 . replace the relay. If there is no continuity. check that there is no continuity between terminals 2 and 4. 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. If there is no continuity. replace the relay. check that there is continuity between terminals 3 and 5. (a) Ohmmeter No Continuity 2 Ohmmeter 1 5 4 Battery 3 Continuity B02804 Inspect the relay operation.

1 Cooling Fan Relay 1. replace the relay.2 cooling fan relay.1) S05390 Ohmmeter 1 Ohmmeter Continuity 3 2 4 Inspect the No. Author : Date : 1607 (c) . replace the relay. If there is no continuity. (Marking: FAN NO.2 cooling fan relay continuity. (2) Using an ohmmeter. (c) Continuity B02801 Ohmmeter 1 (d) No Continuity 3 2 4 Battery Inspect the No.1 COOLING FAN RELAY Remove the relay box cover. Remove the No.1 cooling fan relay operation. (Marking: FAN NO. (1) Apply battery positive voltage across terminals 1 and 2. If there is continuity.CO–33 COOLING (5S–FE) – COOLING FAN RELAY COOLING FAN RELAY CO06V–03 INSPECTION No.1 cooling fan relay continuity. If there is no continuity. Remove the No.1 cooling fan relay (f) Reinstall the relay box cover. (2) Check that there is continuity between terminals 3 and 4. (e) Reinstall the No.2) S05387 Ohmmeter 4 1 Ohmmeter Continuity 2 Ohmmeter 5 3 Continuity No Continuity S04972 Inspect the No.1 cooling fan relay. (2) Check that there is continuity between terminals 3 and 4. (1) Using an ohmmeter. (a) (b) INSPECT NO. replace the relay. replace the relay. check that there is continuity between terminals 1 and 2. (3) Check that there is no continuity between terminals 3 and 5. replace the relay.2 COOLING FAN RELAY Remove the relay box cover. (1) Using an ohmmeter. check that there is no continuity between terminals 3 and 4. If there is no continuity. check that there is continuity between terminals 1 and 2. If there is continuity. B02802 No. (a) (b) INSPECT NO. If there is no continuity.2 Cooling Fan Relay 2. replace the relay.

replace the relay.2 cooling fan relay. check that there is continuity between terminals 1 and 2. Remove the No. (1) Apply battery positive voltage across terminals 1 and 2.CO–34 COOLING (5S–FE) – COOLING FAN RELAY 4 Battery Ohmmeter 1 2 Ohmmeter 5 3 No Continuity Continuity S04971 Inspect the No. replace the relay.3) S05388 Continuity Ohmmeter 1 2 5 Ohmmeter (c) 3 No Continuity S04970 Inspect the No. (f) Reinstall the relay box cover.3 cooling fan relay continuity. If there is continuity. If there is no continuity. (2) Check that there is no continuity between terminals 3 and 5. replace the relay. If there is no continuity.3 COOLING FAN RELAY Remove the relay box cover. (e) Reinstall the No. (2) Using an ohmmeter. (f) Reinstall the relay box cover. check that there is no continuity between terminals 3 and 4 If there is continuity. (e) Reinstall the No.2 cooling fan relay operation. (d) No. (3) Check that there is continuity between terminals 3 and 5. 2 1 5 Ohmmeter 3 Battery Continuity S04969 Inspect the No.3 cooling fan relay operation. If there is no continuity. (d) Author : Date : 1608 . check that there is continuity between terminals 3 and 5. (a) (b) INSPECT NO. replace the relay. (1) Using an ohmmeter. (2) Using an ohmmeter. replace the relay. (Marking: FAN NO.3 cooling fan relay.3 cooling fan relay. (1) Apply battery positive voltage across terminals 1 and 2.3 Cooling Fan Relay 3.

CO–1 COOLING (1MZ–FE) – COOLANT COOLANT CO03B–04 INSPECTION 1. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole. Author : Date : 1609 . do not remove the radiator cap while the engine and radiator are still hot. If low. If excessively dirty. 2. check for leaks and add ’’Toyota Long Life Coolant” or Equivalent up to the ”FULL” line. when the engine is cold. as fluid and steam can be blown out under pressure. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap from the water outlet. clean the coolant passages and replace the coolant. CAUTION: To avoid the danger of being burned. (c) Reinstall the radiator cap. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines. and the coolant should be free from oil.

DRAIN ENGINE COOLANT (a) Remove the radiator cap from the water outlet. 9 ft·lbf) 2. and drain the coolant. z Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 % (freezing protection down to –50°C (–58°F)) of ethylene–glycol is recommended but not more than 70 %. refill coolant into the reservoir up to the ”FULL” line. FILL ENGINE COOLANT (a) Slowly fill the system with coolant. Torque: RH engine drain plug on EGR cooler: 7 N·m (70 kgf·cm. (b) Drain Plug Drain Plug Z18835 Loosen the radiator drain plug and engine drain plugs. z The coolant should be mixed with plain water (preferably demineralized water or distilled water). NOTICE: z Do not use an alcohol type coolant or plain water alone.2 liters (9.·lbf) LH engine drain plug on union: 13 N·m (130 kgf·cm.7 US qts. and bleed the cooling system. 8.CO–2 COOLING (1MZ–FE) – COOLANT CO03C–04 REPLACEMENT 1.1 lmp. z Use ”Toyota Long life Coolant” or equivalent and mix it with plan water according to the manufacturer’s directions. z Use of improper coolants may damage engine cooling system. (d) If necessary. (c) Start the engine. 61 in. do not remove the radiator cap while the engine and radiator are still hot. Capacity: 9. qts) (b) Install the radiator cap. as fluid and steam can be blown out under pressure. CAUTION: To avoid the danger of being burned. 3. CHECK ENGINE COOLANT FOR LEAKS 4. (c) Close the drain plugs. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY Author : Date : 1610 .

2 RH Engine Mounting Stay (M/T) Ground Strap Engine Coolant Reservoir Hose N·m (kgf·cm. ft·lbf) : Specified torque A06654 Author : Date : 1611 . 23) Generator Drive Belt Engine Moving Control Rod 64 (650.CO–3 COOLING (1MZ–FE) – WATER PUMP WATER PUMP CO03D–04 COMPONENTS RH Fender Apron Seal 64 (650. 47) 32 (320. 47) RH Engine Mounting Stay No.2 RH Engine Mounting Bracket PS Pump Drive Belt No.

65) 43 (440. 94) Dust Boot Timing Belt Tensioner N·m (kgf·cm.300. ft·lbf) : Specified torque z Non–reusable part *For use with SST 27 (280. 159) Engine Wire Protector No.2 Idler Pulley RH Camshaft Timing Pulley 125 (1.200. 20) B06388 Author : Date : 1612 . 21) Timing Belt Guide No.1 Timing Belt Cover Crankshaft Pulley Gasket 215 (2.2 Generator Bracket No. 32) LH Camshaft Timing Pulley 125 (1.CO–4 COOLING (1MZ–FE) – WATER PUMP Timing Belt Gasket No. 94) *88 (900.2 Timing Belt Cover RH Engine Mounting Bracket 28 (290.300.

CO–5 COOLING (1MZ–FE) – WATER PUMP Gasket No.3 Timing Belt Cover Collar Bushing x6 8.·lbf) N·m (kgf·cm. ft·lbf) : Specified torque z Non–reusable part B04403 Author : Date : 1613 .·lbf) Engine Wire z Gasket Water Pump 8 (80.5 (85. 74 in. 69 in.

3 TIMING BELT COVER (See page EM–32) 6. 2 nuts. REMOVE WATER PUMP Remove the 4 bolts. 2. P12942 Author : Date : 1614 .CO–6 COOLING (1MZ–FE) – WATER PUMP CO03E–03 REMOVAL 1. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–15) REMOVE CAMSHAFT TIMING PULLEYS (See page EM–15) REMOVE NO. water pump and gasket. 5.2 IDLER PULLEY (See page EM–15) REMOVE NO. 4. 3.

2. replace the water pump.CO–7 COOLING (1MZ–FE) – WATER PUMP CO03F–03 INSPECTION 1. INSPECT WATER PUMP (a) Visually check the drain hole for coolant leakage. and check that the water pump bearing moves smoothly and quietly. If leakage is found. INSPECT TIMING BELT COMPONENTS (See page EM–19) P12487 Author : Date : 1615 . replace the water pump. If necessary. (b) Turn the pulley.

INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. INSTALL TIMING BELT (See page EM–21) 6. START ENGINE AND CHECK FOR LEAKS 8. INSTALL NO. Torque: 8 N·m (80 kgf·cm. INSTALL NO.2 IDLER PULLEY (See page EM–21) 4. FILL WITH ENGINE COOLANT 7.·lbf) NOTICE: Do not get oil on the gasket. 2. RECHECK ENGINE COOLANT LEVEL P12942 Author : Date : 1616 .3 TIMING BELT COVER (See page EM–57) 3. 69 in.CO–8 COOLING (1MZ–FE) – WATER PUMP CO0SO–01 INSTALLATION 1. INSTALL CAMSHAFT TIMING PULLEYS (See page EM–21) 5.

14) N·m (kgf·cm.2 ECT Switch Connector Air Filter Engine Wire Protector Thermostat z Gasket Water Inlet z O–Ring Water Inlet Pipe 8 (80.·lbf) 19. ft·lbf) : Specified torque z Non–reusable part B06397 Author : Date : 1617 .5 (200.CO–9 COOLING (1MZ–FE) – THERMOSTAT THERMOSTAT CO03H–03 COMPONENTS MAF Meter Connector EGR Vacuum Hose EVAP Hose Air Cleaner Cap Assembly No. 69 in.

DRAIN ENGINE COOLANT 2. (a) (b) REMOVE WATER INLET AND THERMOSTAT Remove the 3 nuts. Remove the gasket from the thermostat. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR FILTER 3. Do not remove the thermostat. DISCONNECT NO. and disconnect the engine wire protector from the water inlet and cylinder head. and disconnect the inlet pipe from the water inlet. S04503 Author : Date : 1618 . DISCONNECT ENGINE WIRE PROTECTOR FROM WATER INLET AND RH CYLINDER HEAD Remove the 2 nuts. S04502 6. 1.2 ECT SWITCH CONNECTOR 4.CO–10 COOLING (1MZ–FE) – THERMOSTAT CO03I–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect. causing a lowering of cooling efficiency. (a) (b) DISCONNECT WATER INLET PIPE FROM WATER INLET AND LH CYLINDER HEAD Remove the bolt. S04581 5. even if the engine tends to overheat. water inlet and thermostat. Remove the O–ring from the inlet pipe.

394 in. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified. Valve lift: 10.) or more at 95°C (203°F) If the valve lift is not as specified. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed. (a) CO0601 Check the valve lift. replace the thermostat. replace the thermostat. P13255 Immerse the thermostat in water and gradually heat the water. 10 mm Z10579 (c) Author : Date : 1619 . replace the thermostat.0 mm (0.CO–11 COOLING (1MZ–FE) – THERMOSTAT CO03J–03 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. (b) Check the valve opening temperature.

CO–12 COOLING (1MZ–FE) – THERMOSTAT CO03K–03 INSTALLATION 1. (b) Align the thermostat jiggle valve with the upper stud bolt. 15° 15° Jiggle Valve Stud Bolt S04532 HINT: The jiggle valve may be set within 15° of either side of the prescribed position. (d) Install the bolt holding the water inlet pipe to the cylinder head. Torque: 8 N·m (80 kgf·cm. CONNECT NO.2 ECT SWITCH CONNECTOR 6. START ENGINE AND CHECK FOR LEAKS 9. INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe.5 N·m (200 kgf·cm. INSTALL WATER INLET Install the water inlet with the 3 nuts. RECHECK ENGINE COOLANT LEVEL Author : Date : 1620 . Torque: 19. and insert the thermostat in the water inlet housing. 2. 14 ft·lbf) 4. INSTALL ENGINE WIRE PROTECTOR 5. (b) Apply soapy water to the O–ring. FILL WITH ENGINE COOLANT 8.·lbf) 3. 69 in. (c) Connect the water inlet pipe to the water inlet. (a) PLACE THERMOSTAT IN WATER PUMP Install a new gasket on to the thermostat. REINSTALL AIR FILTER AND AIR CLEANER CAP ASSEMBLY 7.

remove any mud or dirt from the radiator core. (i.CO–13 COOLING (1MZ–FE) – RADIATOR RADIATOR CO03L–03 ON–VEHICLE CLEANING Using water or a steam cleaner. NOTICE: If using a high pressure type cleaner.e. be careful not to deform the fins of the radiator core. Maintain a distance between the cleaner nozzle and radiator core) Author : Date : 1621 .

15 kgf/cm2. replace the radiator cap. If the opening pressure is less than minimum. keep the radiator cap tester at an angle of over 30° above the horizontal. INSPECT RADIATOR CAP NOTICE: z If the radiator cap has contaminations.7 kgf/cm2. slowly pump the tester and check that air is coming from the vacuum valve. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned. 2. replace the radiator cap. z Before using a radiator cap tester. as fluid and steam can be blow out under pressure.1 – 16. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. do not remove the radiator cap while the engine and radiator are still hot. 12. (a) Author : Date : 1622 . If air is not coming from the vacuum valve. Standard opening pressure: 83 – 113 kPa (0.0 psi) HINT: Use the tester’s maximum reading as the 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). Radiator Cap Tester 30° or More Radiator Cap Z00570 Using a radiator cap tester. 10.4 psi) Minimum opening pressure: 69 kPa (0. the pump speed can be reduced. After this. always rinse it with water.85 – 1. (b) Pump the tester and measure the relief valve opening pressure. wet the relief valve and pressure valve with engine coolant or water.CO–14 COOLING (1MZ–FE) – RADIATOR CO03M–03 ON–VEHICLE INSPECTION 1. z When performing steps (a) and (b) below.

(a) Author : Date : 1623 . check the hoses. If no external leaks are found.5 psi). If the pressure drops. 4.3 kgf/cm2. (c) Pump it to 127 kPa (1. (b) Warm up the engine. 18.CO–15 COOLING (1MZ–FE) – RADIATOR Radiator Cap Tester P13014 INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. check the heater core. radiator or water pump for leaks. and check that the pressure does not drop. REINSTALL RADIATOR CAP 3. cylinder block and cylinder head.

1 ECT Switch No.1 Cooling Fan Connector Radiator Assembly Lower Radiator Hose Lower Radiator Support Drain Plug z O–Ring Lower Radiator Support No.1 ECT Switch Wire Upper Radiator Hose Upper Radiator Support No.2 Cooling Fan No.1 Cooling Fan z O–Ring No.CO–16 COOLING (1MZ–FE) – RADIATOR CO03N–03 COMPONENTS A/T Oil Cooler Hose Radiator No.2 Cooling Fan Connector Upper Radiator Support No.1 ECT Switch Wire Connector Relay Block (for Daytime Running Light System) Lower Radiator Hose A/T Oil Cooler Hose z Non–reusable part B06399 Author : Date : 1624 .

CO–17 COOLING (1MZ–FE) – RADIATOR Upper Tank z O–Ring A/T Oil Cooler Cushion Core Inlet Pipe z O–Ring Plate Washer Nut Lower Tank z O–Ring z Non–reusable part S04606 Author : Date : 1625 .

Start the engine. 9 ft·lbf) Lift out the radiator. 4. Remove the 2 lower supports. 6. 7. Check the A/T fluid level. Lower Hose 9. 2. REMOVE A/T OIL COOLER HOSES FROM RADIATOR REMOVE LOWER RADIATOR HOSE FROM RADIATOR Oil Cooler Hose B05937 Author : Date : 1626 . (See page DI–438) DRAIN ENGINE COOLANT CANADA: DISCONNECT RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) FROM BATTERY HOLD–DOWN 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. 3.CO–18 COOLING (1MZ–FE) – RADIATOR CO03O–03 REMOVAL HINT: z z z 1. and remove the radiator and cooling fans assembly. Torque: 12. (a) (b) (c) S04725 REMOVE RADIATOR AND COOLING FANS ASSEMBLY Remove the 2 bolts and 2 upper supports. 5.8 N·m (130 kgf·cm.2 COOLING FAN CONNECTORS DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR 8. and check for coolant and A/T fluid leaks. please refer to the following items.1 AND NO. 10. At the time of installation.

REMOVE NO. Torque: 5.1 No. REMOVE NO. 44 in. 44 in.CO–19 COOLING (1MZ–FE) – RADIATOR 11. REMOVE NO.1 ECT SWITCH S04588 No.1 COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan.0 N·m (50 kgf·cm.2 COOLING FAN FROM RADIATOR Remove the 3 bolts and cooling fan.2 12.0 N·m (50 kgf·cm. Torque: 5.·lbf) B05938 Author : Date : 1627 .·lbf) 13.

2. SST 09230–01010 Stopper Bolt S04737 4. adjust the stopper bolt so that dimension ”B” shown in the diagram is 0.). (a) Tap (b) REMOVE TANKS AND O–RINGS Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft–faced hammer and remove the tank. Z18546 Author : Date : 1628 . (b) While gripping the handle. Remove the oil cooler and O–rings. UNCAULK LOCK PLATES Using SST to release the caulking. Dimension ”B” SST Stopper Bolt Claw Overhaul Handle CO1205 Tank Lock Plate SST 3. Remove the nuts and plate washers. REMOVE CUSHION FROM RADIATOR ASSEMBLE SST SST 09230–01010 (a) Install the claw to the overhaul handle.020 in. S04738 A/T 5. squeeze the handle until stopped by the stopper bolt.CO–20 COOLING (1MZ–FE) – RADIATOR CO03P–03 Part ”A” DISASSEMBLY 1. (a) (b) (c) A/T: REMOVE OIL COOLER FROM LOWER TANK Remove the pipe.008 – 0. Remove the O–ring. the claw may be damaged. NOTICE: If this adjustment is not done. inserting it in the hole in part ”A” as shown in the diagram.2 – 0.5 mm (0.

Install the oil cooler with the O–rings to the lower tank (3). Torque the nuts. 74 in. After the 2nd time. O–Ring X Twisted CO0317 Author : Date : 1629 . lightly rub it with sand paper without scratching it. (a) f Normal X Twisted INSTALL NEW O–RINGS AND TANKS After checking that there are no foreign objects in the lock plate groove. z Therefore. HINT: z If the sides of the lock plate groove are deformed. Torque: 14. 11 ft·lbf) Lock Plate Lock Plate Core CO1267 2. the radiator core must be replaced.·lbf) Install the pipe (6). 3.3 N·m (85 kgf·cm. install the new O–ring without twisting it. INSPECT LOCK PLATE Inspect the lock plate for damage. and nuts (5). Torque: 8. Therefore. repair or replace if necessary.CO–21 COOLING (1MZ–FE) – RADIATOR CO03Q–03 A/T (2) (1) (6) REASSEMBLY 1. NOTICE: The radiator can only be recaulked 2 times. Install a new O–rings (1) to the oil cooler (2). Water leakage will result if the bottom of the lock plate groove is damaged or dented.7 N·m (150 kgf·cm. (a) (5) (4) Z18506 (3) (b) (c) (d) (e) A/T: INSTALL OIL COOLER TO LOWER TANK Clean the O–ring contact surface of the lower tank and oil cooler. first correct any deformation with pliers or similar object. HINT: When cleaning the lock plate groove. Install the plate washers (4). reassembly of the tank will be impossible.

4 mm (0. 09231–14010 Install the punch assembly to the overhaul handle. Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. Dimension ”B”: 8. inserting it in the hole in part ”A” as shown in the illustration. (a) 7 2 4 SST 8 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times. Bracket S04734 Author : Date : 1630 . fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. Tap 4.CO–22 COOLING (1MZ–FE) – RADIATOR CORRECT Tank WRONG Lock Plate S04736 (b) (c) Install the tank without damaging the O–ring. adjust the stopper bolt so that dimension ”B” shown in the diagram. SST 09230–01010 St opper Bolt Tank Lock Plate S04739 Rib HINT: z Do not stake the areas protruding around the pipes. While gripping the handle.34 in. Part ”A” (a) Dimension ”B” SST (b) Stopper Bolt ASSEMBLE SST SST 09230–01010. brackets or tank ribs.) Punch Assembly Overhaul Handle CO1206 5 1 6 3 5.

CO–23 COOLING (1MZ–FE) – RADIATOR z The points shown in the rib sides and oil cooler near here cannot be staked with SST.8 mm (0.4 – 7. adjust the stopper bolt of the handle again and caulk again. S04726 (b) Check the lock plate height (H) after completing the caulking.2959 – 0. 6. Plate height (H): 7.3119 in. Use pliers or similar object and be careful not to damage the core plates. INSTALL CUSHION H S04735 Author : Date : 1631 .) If not within the specified height.

CO–24 COOLING (1MZ–FE) – RADIATOR CO03R–01 INSTALLATION Installation is in the reverse order of removal. (See page CO–18) Author : Date : 1632 .

If not. engine main relay. 1.3 – 11. (c) Disconnect the No. cooling fan. (a) (b) (c) (d) Battery B05941 INSPECT NO. B05940 CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 98°C (208°F)) (a) Start the engine. cooling fan relay. If not. and check for a separated connector or severed wire between the cooling fan relay and ECT switch. and check for a short circuit between the cooling fan relay and ECT switch. replace the No. check the cooling fan relay and ECT switch. and check the reading on the ammeter. (b) Check that the cooling fan stops. B05939 Disconnect S04727 (d) Check that the cooling fan rotates. and raise coolant temperature to above 98°C (208°F). (b) Check that the cooling fan rotates. Connect battery and ammeter to the cooling fan connector.1 ECT switch connector. If not. Standard amperage: 8.1 ECT switch connector. Author : Date : 1633 .1 COOLING FAN Disconnect the cooling fan connector.CO–25 COOLING (1MZ–FE) – ELECTRIC COOLING FAN ELECTRIC COOLING FAN CO03S–03 ON–VEHICLE INSPECTION CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 88°C (190°F)) (a) Turn the ignition switch ON. (e) Reconnect the No. 2.3 A at 20°C (68°F) Reconnect the cooling fan connector. check the fuses.1 ECT switch. Ammeter 3. Check that the cooling fan rotates smoothly.

Author : Date : 1634 .3 – 11. and check the reading on the ammeter. (a) (b) (c) (d) Battery B05942 INSPECT NO. Standard amperage: 8. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly.3 A at 20°C (68°F) Reconnect the cooling fan connector.2 COOLING FAN Disconnect the cooling fan connector.CO–26 COOLING (1MZ–FE) – ELECTRIC COOLING FAN Ammeter 4.

CO–27 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03T–03 COMPONENTS No.1 Cooling Fan Connector No.1 ECT Switch Connector No.1 Cooling Fan No.1 ECT Switch Wire Relay Block (for Daytime Running Light System) z Non–reusable part B06400 Author : Date : 1635 .1 Fan Fan Motor z Clip Fan Shroud No.

2 Cooling Fan Upper Radiator Hose z Non–reusable part B06402 Author : Date : 1636 .2 Cooling Fan Connector No.2 Fan Fan Motor z Clip Fan Shroud No.CO–28 COOLING (1MZ–FE) – ELECTRIC COOLING FAN No.

0 N·m (50 kgf·cm. (a) REMOVE NO. Disconnect the cooling fan connector.CO–29 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03U–03 REMOVAL 1.1 COOLING FAN Canada: Disconnect the relay block (for daytime running light system) from the battery hold–down clamp. Disconnect the upper radiator hose from the radiator. (a) (b) (c) REMOVE NO.2 COOLING FAN Drain the engine coolant. 44 in.1 ECT switch wire connector.·lbf) B05943 2.1 ECT switch wire clamps.0 N·m (50 kgf·cm. Disconnect the No. Torque: 5. (d) Remove the 3 bolts and cooling fan. 44 in.·lbf) B05944 Author : Date : 1637 . Disconnect the No. (b) (c) (d) (e) Remove the 2 bolts and cooling fan. Disconnect the cooling fan connector. Torque: 5.

Author : Date : 1638 . REMOVE NO. S04584 (c) Remove the 3 screws and fan motor. S04587 Protrusion B05946 2. Install a new clip from the side opposite the protrusion on the fan. do not apply too much force to the motor shaft.CO–30 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03V–03 Protrusion DISASSEMBLY 1. And do not scratch the motor shaft. HINT: At the time of installation. HINT: At the time of installation. And do not scratch the motor shaft. please refer to the following items. please refer to the following items. REMOVE NO. NOTICE: When removing the clip and fan. B05945 (b) Disconnect the lead wire from the fan shroud.2 COOLING FAN (a) Remove the clip and fan. do not apply too much force to the motor shaft.1 COOLING FAN (a) Remove the clip and fan. Install a new clip from the side opposite the protrusion on the fan. NOTICE: When removing the clip and fan.

CO–31 COOLING (1MZ–FE) – ELECTRIC COOLING FAN (b) Disconnect the lead wire from the fan shroud. S04586 Author : Date : 1639 . S04585 (c) Remove the 3 screws and fan motor.

(See page CO–30) Author : Date : 1640 .CO–32 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03W–01 REASSEMBLY Reassembly is in the reverse order of disassembly.

CO–33 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03X–01 INSTALLATION Installation is in the reverse order of removal. (See page CO–29) Author : Date : 1641 .

(c) Reinstall the No. DRAIN ENGINE COOLANT 2.1 ECT switch. If there is no continuity. 3.CO–34 COOLING (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO03Y–04 INSPECTION 1.1 ECT switch.2 ECT SWITCH (a) Remove the No. (2) Check that there is no continuity between the terminals when the coolant temperature is below 83°C (181°F). between the terminals when the coolant temperature is below 88°C (190°F).1 ECT Switch S04602 Ohmmeter P01924 Inspect the No. No. replace the switch.2 ECT switch.2 ECT Switch S04601 Ohmmeter P06722 Inspect the No.2 ECT switch. replace the switch. replace the switch.1 ECT SWITCH Remove the No. check that there is no continuity between the terminals when the coolant temperature is above 98°C (208°F). If there is no continuity. Author : Date : 1642 (b) . INSPECT NO. (2) Check that there is continuity. If there is continuity. (1) Using an ohmmeter.2 ECT switch. replace the switch. (b) No. (c) Reinstall the No. (a) INSPECT NO.1 ECT switch. If there is continuity. (1) Using an ohmmeter. check that there is continuity between terminals when the coolant temperature is above 94°C (201°F).

REFILL ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author : Date : 1643 .CO–35 COOLING (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH 4. 5.

If there is no continuity. Using an ohmmeter. REINSTALL RELAY BOX COVER Ohmmeter No Continuity 2 1 Ohmmeter 5 4 Battery 3 Continuity S04973 Author : Date : 1644 . (c) Check that there is no continuity between terminals 1 and 2. REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE MAIN) S05391 Ohmmeter Continuity 2 1 Ohmmeter 3. 4. If there is no continuity. replace the relay. (b) Check that there is continuity between terminals 2 and 4. replace the relay. replace the relay. (a) (b) INSPECT RELAY OPERATION Apply battery positive voltage across terminals 3 and 5. REINSTALL ENGINE MAIN RELAY 6.CO–36 COOLING (1MZ–FE) – ENGINE MAIN RELAY ENGINE MAIN RELAY CO03Z–03 INSPECTION Engine Main Relay 1. (c) Check that there is continuity between terminals 1 and 2. (a) Ohmmeter 5 4 Continuity 3 No Continuity S04974 INSPECT RELAY CONTINUITY Using an ohmmeter. 5. If there is continuity. check that there is no continuity between terminals 2 and 4. check that there is continuity between terminals 3 and 5. If there is continuity. If there is no continuity. replace the relay. replace the relay. 2.

(2) Check that there is continuity between terminals 3 and 4. If there is no continuity. check that there is continuity between terminals 1 and 2.1 COOLING FAN RELAY Remove the No. No. (a) REMOVE RELAY BOX COVER INSPECT NO. replace the relay. check that there is continuity between terminals 1 and 2. (Marking: FAN NO. If there is no continuity. (b) S04975 Ohmmeter No Continuity 1 4 3 2 Battery S04976 (c) Inspect the No. replace the relay. replace the relay.2 cooling fan relay. (3) Check that there is no continuity between terminals 3 and 5.2) S05387 Ohmmeter 4 1 Ohmmeter 3 Continuity No Continuity S04972 2 5 Ohmmeter Inspect the No.1 cooling fan relay continuity. (Marking: FAN NO. replace the relay. (1) Apply battery positive voltage across terminals 1 and 2. (1) Using an ohmmeter. (2) Using an ohmmeter.1 cooling fan relay operation. If there is continuity. (2) Check that there is continuity between terminals 3 and 4.2 COOLING FAN RELAY Remove the No.2 Cooling Fan Relay 3. (1) Using an ohmmeter. If there is continuity.1) S05390 Ohmmeter Continuity 1 4 3 2 Continuity Ohmmeter Inspect the No.1 cooling fan relay. Author : Date : 1645 (b) .1 cooling fan relay.1 Cooling Fan Relay 1.CO–37 COOLING (1MZ–FE) – COOLING FAN RELAY COOLING FAN RELAY CO040–03 INSPECTION No. replace the relay. If there is no continuity. replace the relay. (a) INSPECT NO. check that there is no continuity between terminals 3 and 4. If there is no continuity. (d) Reinstall the No. 2.2 cooling fan relay continuity.

If there is mo continuity. If there is continuity. (2) Using an ohmmeter. REINSTALL RELAY BOX COVER Author : Date : 1646 .2 cooling fan relay operation.3 cooling fan relay operation.CO–38 COOLING (1MZ–FE) – COOLING FAN RELAY (c) 4 1 2 Ohmmeter 5 Battery Ohmmeter 3 No Continuity Continuity S04971 Inspect the No. (1) Apply battery positive voltage across terminals 1 and 2.3 cooling fan relay. check that there is continuity between terminals 3 and 5. If there is no continuity. (1) Apply battery positive voltage across terminals 1 and 2.3 Cooling Fan Relay 4. (b) (c) 2 1 5 Ohmmeter 3 Battery Continuity S04969 Inspect the No. 5.3 cooling fan relay. replace the relay. (1) Using an ohmmeter. If there is continuity. (Marking: FAN NO.3) S05388 Continuity Ohmmeter 1 2 5 Ohmmeter 3 No Continuity S04970 Inspect the No.3 COOLING FAN RELAY Remove the No.2 cooling fan relay. (2) Check that there is no continuity between terminals 3 and 5. replace the relay. replace the relay. (d) Reinstall the No. (a) INSPECT NO.3 cooling fan relay continuity. check that there is continuity between terminals 1 and 2. (d) Reinstall the No. No. (2) Using an ohmmeter. check that there is no continuity between terminals 3 and 4. replace the relay.