Engine Cooling System (Service Information): Removal & Installation Scion FR-S I

INSTALLATION [07/2013 - ]

1. INSTALL ENGINE WATER PUMP ASSEMBLY Install a new water pump gasket and the engine water pump assembly with the 5 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
2. INSTALL WATER PUMP PULLEY Temporarily install the water pump pulley with the 3 bolts. Using SST, hold the water pump pulley and tighten the 3 bolts. SST: 09960-10010 09962-01000 09963-00700 Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTE: Be careful not to let SST slip during the work.
3. INSTALL EXHAUST MANIFOLD Refer to «INSTALLATION [07/2013 - ]»(ref-612378-S08672258382014042900000)
4. INSTALL FAN AND GENERATOR V BELT Refer to «INSTALLATION [07/2013 - ]»(ref-612349-S26798289872014042900000)
5. ADD ENGINE COOLANT See step 2
6. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [07/2013 - ] - Step 1»(ref-612352-S22062286662014042900000)
7. INSTALL NO. 1 ENGINE UNDER COVER

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1. REMOVE EXHAUST MANIFOLD Refer to «REMOVAL [07/2013 - ]»(ref-612378-S30087077872014042900000)
2. DRAIN ENGINE COOLANT See step 1
3. SEPARATE OUTLET RADIATOR HOSE Loosen the hose clamp and disconnect the outlet radiator hose from the water outlet. HINT: Since the radiator hose must be attached in the correct position, apply matchmarks before removing it.
4. REMOVE WATER OUTLET Remove the 2 bolts and water outlet.
5. REMOVE THERMOSTAT Remove the thermostat. Remove the thermostat gasket from the thermostat.

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1. INSPECT THERMOSTAT Immerse the thermostat in water and then gradually heat the water. HINT: Hold the thermostat with a wire or the like, so that the thermostat does not come into contact with the bottom of the container. Check the valve opening temperature of the thermostat. Standard valve opening temperature 86 to 90 °C (187 to 194 °F) HINT: If the valve opening temperature is not as specified, replace the thermostat. Check the valve opening temperature. Check the valve lift. TEXT IN ILLUSTRATION *a Valve lift Valve lift 8.0 mm (0.315 in.) or more at 95 °C (203 °F) HINT: If the valve lift value is not as specified, replace the thermostat. When the temperature of the thermostat drops below 83 °C (181 °F), check that the valve is fully closed. HINT: If the valve is not fully closed, replace the thermostat.

1. INSTALL THERMOSTAT Install a new thermostat gasket to the thermostat. Install the thermostat to the water outlet.
2. INSTALL WATER OUTLET Install the water outlet with the 2 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
3. CONNECT OUTLET RADIATOR HOSE Since the radiator hose must be attached in the correct position, apply matchmarks before removing it. Connect the outlet radiator hose to the water outlet with the hose clamp.
4. ADD ENGINE COOLANT See step 2
5. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [07/2013 - ] - Step 1»(ref-612352-S22062286662014042900000)
6. INSTALL EXHAUST MANIFOLD Refer to «INSTALLATION [07/2013 - ]»(ref-612378-S08672258382014042900000)

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1. DRAIN COOLANT See step 1
2. REMOVE INTAKE MANIFOLD Refer to «REMOVAL [07/2013 - ]»(ref-612378-S26002182462014042900000)
3. DISCONNECT WATER HOSE Loosen the hose clamp and disconnect the water hose from the water inlet housing.
4. DISCONNECT WATER INLET HOUSING Remove the 2 bolts and water inlet housing.
5. REMOVE THERMOSTAT Remove the thermostat. Remove the gasket from the thermostat.

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1. INSPECT THERMOSTAT Immerse the thermostat in water and then gradually heat the water. HINT: Hold the thermostat with a wire or the like, so that the thermostat does not come into contact with the bottom of the container. Check the valve opening temperature of the thermostat. Valve opening temperature 48 to 52°C (118 to 126°F) HINT: If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. TEXT IN ILLUSTRATION *a Valve Lift Valve lift 6.0 mm (0.236 in.) or more at 63°C (145°F) HINT: If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the water inlet with thermostat is at low temperatures (below 45°C (113°F)). HINT: If it is not fully closed, replace the thermostat.

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1. INSTALL THERMOSTAT Install a new gasket to the thermostat. Install the thermostat to the water inlet housing as shown in the illustration. TEXT IN ILLUSTRATION *1 Jiggle Valve Upper Side HINT: The jiggle valve must be set within 10° on either side of the position shown in the illustration.
2. CONNECT WATER INLET HOUSING Install the water inlet housing with the 2 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
3. CONNECT WATER HOSE Connect the water hose to the water inlet housing with the hose clamp.
4. ADD COOLANT See step 2
5. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [07/2013 - ] - Step 1»(ref-612352-S22062286662014042900000)
6. INSTALL INTAKE MANIFOLD Refer to «INSTALLATION [07/2013 - ]»(ref-612378-S13408599112014042900000)

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1. INSPECT COOLING FAN MOTOR Check that the motor operates smoothly when the battery is connected to the cooling fan motor connector. TEXT IN ILLUSTRATION *a Component without harness connected (Cooling fan motor) If the motor does not operate smoothly, replace the cooling fan motor. Measure the current while the motor is operating. Standard Current Item Condition Specified Condition Cooling fan motor 20°C (68°F) 7.4 to 11.4 A at 12 V If the result is not as specified, replace the cooling fan motor.
2. INSPECT NO. 2 COOLING FAN MOTOR Check that the motor operates smoothly when the battery is connected to the No. 2 cooling fan motor connector. TEXT IN ILLUSTRATION *a Component without harness connected (No. 2 cooling fan motor) If the motor does not operate smoothly, replace the No. 2 cooling fan motor. Measure the current while the motor is operating. Standard Current Item Condition Specified Condition No. 2 cooling fan motor 20°C (68°F) 7.4 to 11.4 A at 12 V If the result is not as specified, replace the No. 2 cooling fan motor.

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1. REMOVE AIR CLEANER CASE SUB-ASSEMBLY See step 1
2. REMOVE FRONT BUMPER COVER Refer to «REMOVAL [07/2013 - ]»(ref-612392-S38518786412014042900000)
3. REMOVE AIR CLEANER DUCT See step 7
4. REMOVE RADIATOR COVER PLATE See step 8
5. REMOVE RADIATOR RESERVE TANK ASSEMBLY See step 6
6. REMOVE WATER FILLER SUB-ASSEMBLY Remove the 4 bolts and separate the water filler sub-assembly.
7. DISCONNECT HOOD LOCK ASSEMBLY . Refer to «REMOVAL [07/2013 - ] - Step 5»(ref-612393-S21313854842014042900000)
8. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY See step 11
9. REMOVE FAN SHROUD Disconnect the 2 wire harness clamps and the 2 cooling fan motor connectors. TEXT IN ILLUSTRATION *1 Cooling fan motor connector *2 No. 2 cooling fan motor connector NOTE: Be careful not to damage the connectors. Mark the sponge on the upper surface of the fan shroud, and use scissors, etc. to cut the sponge. HINT: Cut the radiator packing at the position between the corner of the radiator packing and the edge of the fun shroud. TEXT IN ILLUSTRATION *1 Cutting Line Detach the 2 claws and separate the fan shroud from the radiator assembly. TEXT IN ILLUSTRATION *1 Cardboard or Blanket *2 Fan shroud HINT: Insert a cardboard or a blanket between the radiator assembly and the fan shroud to protect the radiator assembly. Remove the fan shroud from the radiator assembly. NOTE: Do not apply any excessive force to the outlet radiator hose, inlet radiator hose, No. 1 radiator hose, pipe or water filler sub-assembly when removing the fan shroud.
10. REMOVE FAN Remove the nut and fan.
11. REMOVE NO. 2 FAN Remove the nut and No. 2 fan.
12. REMOVE COOLING FAN MOTOR Disengage the connector clamp, and disconnect the connector from cooling fan motor. Remove the 3 screws and cooling fan motor.
13. REMOVE NO. 2 COOLING FAN MOTOR Remove the 3 screws and the No. 2 cooling fan motor.

1. INSTALL NO. 2 COOLING FAN MOTOR Install the No. 2 cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
2. INSTALL COOLING FAN MOTOR Install the cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) Connect the wire harness to the 2 cooling fan motors.
3. INSTALL NO. 2 FAN Install the No. 2 fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
4. INSTALL FAN Install the fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
5. INSTALL FAN SHROUD HINT: Insert a cardboard or a blanket between the radiator assembly and the fan shroud to protect the radiator assembly. Engage the fitting sections in the bottom of the fan shroud with the fitting sections of the radiator assembly. NOTE: Do not damage the outlet radiator hose, inlet radiator hose, No. 1 radiator hose, water filler sub-assembly, or air conditioner tube and accessory assembly. Attach the 2 claws and install the fan shroud to the radiator assembly. Connect the 2 cooling fan motor connectors and 2 clamps to the radiator assembly.
6. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY See step 11
7. INSTALL RADIATOR COVER PLATE See step 14
8. REMOVE AIR CLEANER DUCT See step 15
9. CONNECT HOOD LOCK ASSEMBLY . Refer to «INSTALLATION [07/2013 - ] - Step 2»(ref-612393-S30787538092014042900000)
10. INSTALL WATER FILLER SUB-ASSEMBLY Install the water filler sub-assembly with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
11. INSTALL RADIATOR RESERVE TANK ASSEMBLY See step 16
12. INSTALL FRONT BUMPER COVER Refer to «INSTALLATION [07/2013 - ]»(ref-612392-S29542371062014042900000)
13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY See step 15

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1. CHECK RADIATOR CAP SUB-ASSEMBLY Measure the valve opening pressure. If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. Check that rubber packings 1, 2 or 3 are not deformed, cracked or swollen. Check that rubber packings 3 and 4 are not stuck together. Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. When using the cap tester, tilt it 30° or more. TEXT IN ILLUSTRATION *1 Radiator Cap Tester *2 Radiator cap sub-assembly *a 30° or more Pump the cap tester several times, and check the maximum pressure*1. Pumping speed 1 pump per second HINT: *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criterion Item Specified Condition Standard valve (for brand-new cap) 93 to 123 kPa (0.95 to 1.25 kgf/cm 2 , 14 to 18 psi) Minimum standard valve (for used cap) 83 kPa (0.85 kgf/cm 2 , 12 psi) If the maximum pressure is less than the minimum standard valve, replace the radiator cap sub-assembly.

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1. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Loosen the hose clamp and disconnect the hose. Disconnect the mass air flow meter connector. Disengage the clamp and disconnect the wire harness. Loosen the 2 hose clamps and disconnect the air cleaner duct and air intake boot. Remove the 3 bolts and the air cleaner case sub-assembly.
2. REMOVE FRONT BUMPER COVER Refer to «REMOVAL [07/2013 - ]»(ref-612392-S38518786412014042900000)
3. REMOVE NO. 1 ENGINE UNDER COVER . Refer to «REMOVAL [07/2013 - ] - Step 1»(ref-612378-S00142194672014042900000)
4. DRAIN ENGINE COOLANT See step 1
5. DISCONNECT OUTLET RADIATOR HOSE See step 3
6. REMOVE RADIATOR RESERVE TANK ASSEMBLY Remove the 2 bolts and radiator reserve tank assembly.
7. REMOVE AIR CLEANER DUCT Remove the 2 bolts and air cleaner duct.
8. REMOVE RADIATOR COVER PLATE Remove the 6 clips and radiator cover plate.
9. REMOVE WATER FILLER SUB-ASSEMBLY Disconnect the radiator cap hose. Detach the 2 water hose clamps. Disconnect the inlet radiator hose and No. 1 radiator hose. HINT: Since the radiator hose must be attached in the correct position, apply matchmarks before removing it. Remove the 4 bolts and the water filler sub-assembly with water filler bracket.
10. REMOVE HOOD LOCK ASSEMBLY . Refer to «REMOVAL [07/2013 - ] - Step 5»(ref-612393-S21313854842014042900000)
11. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY Remove the 2 bolts. Remove the 4 bolts and radiator support sub-assembly.
12. SEPARATE COOLER CONDENSER ASSEMBLY Remove the bolt. Remove the bolt. Remove the bolt. Remove the bolt A. Remove the bolt B and separate the cooler condenser assembly from the radiator assembly.
13. REMOVE FAN SHROUD See step 9
14. REMOVE RADIATOR ASSEMBLY Remove the 2 bolts and radiator support RH. Remove the 2 bolts and radiator support LH. Detach the claw and disconnect the thermistor assembly. While lifting the outlet radiator hose, remove the radiator assembly. NOTE: Insert cardboard or a blanket between the radiator assembly and the cooler condenser assembly to protect the cooler condenser assembly. TEXT IN ILLUSTRATION *1 Cooler condenser assembly *2 Cardboard or Blanket *3 Radiator assembly Remove the 2 radiator support cushions.
15. REMOVE INLET RADIATOR HOSE Remove the clamp and the inlet radiator hose from the water filler sub-assembly. HINT: Since the radiator hose must be attached in the correct position, apply matchmarks before removing it.
16. REMOVE NO. 1 RADIATOR HOSE Remove the clamp and No. 1 radiator hose from the radiator assembly. TEXT IN ILLUSTRATION *1 No. 1 radiator hose HINT: Since the radiator hose must be attached in the correct position, apply matchmarks before removing it.
17. REMOVE OUTLET RADIATOR HOSE Remove the clamp and outlet radiator hose from the radiator assembly. TEXT IN ILLUSTRATION *1 Outlet radiator hose HINT: Since the radiator hose must be attached in the correct position, apply matchmarks before removing it.
18. REMOVE RADIATOR PACKING (UPPER) Remove the radiator packing. TEXT IN ILLUSTRATION *1 Radiator Packing
19. REMOVE NO. 1 RADIATOR PACKING Remove the No. 1 radiator packing. TEXT IN ILLUSTRATION *1 No. 1 Radiator Packing
20. REMOVE NO. 2 RADIATOR PACKING Remove the No. 2 radiator packing. TEXT IN ILLUSTRATION *1 No. 2 Radiator Packing
21. REMOVE RADIATOR PACKING (LOWER) Remove the radiator packing. TEXT IN ILLUSTRATION *1 Radiator Packing

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1. INSTALL RADIATOR PACKING (LOWER) Install the new radiator packing.
2. INSTALL NO. 2 RADIATOR PACKING Install the new No. 2 radiator packing.
3. INSTALL NO. 1 RADIATOR PACKING Install the new No. 1 radiator packing.
4. INSTALL RADIATOR PACKING (UPPER) Install the new radiator packing. TEXT IN ILLUSTRATION *1 Radiator Packing HINT: Cut the radiator packing at the same position in the removal.
5. INSTALL OUTLET RADIATOR HOSE Since the radiator hose must be attached in the correct position, apply matchmarks before removing it. Install the outlet radiator hose to the radiator assembly and secure it with the clamp.
6. INSTALL NO. 1 RADIATOR HOSE Since the radiator hose must be attached in the correct position, apply matchmarks before removing it. Install the No. 1 radiator hose to the water filler sub-assembly and secure it with the clamp.
7. INSTALL INLET RADIATOR HOSE Since the radiator hose must be attached in the correct position, apply matchmarks before removing it. Install the inlet radiator hose to the radiator assembly and secure it with the clamp.
8. INSTALL RADIATOR ASSEMBLY Install the 2 radiator support cushions to the radiator assembly. While lifting the outlet radiator hose, install the radiator assembly. NOTE: Push a blanket or a cardboard against the cooler condenser assembly to protect it. Attach the claw and install the thermistor assembly. Install the radiator support RH with the 2 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Install the radiator support LH with the 2 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
9. INSTALL FAN SHROUD See step 5
10. INSTALL COOLER CONDENSER ASSEMBLY Install the cooler condenser assembly to the radiator assembly with the 5 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
11. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY Install the 6 bolts and radiator support sub-assembly. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
12. INSTALL HOOD LOCK ASSEMBLY . Refer to «INSTALLATION [07/2013 - ] - Step 2»(ref-612393-S30787538092014042900000)
13. INSTALL WATER FILLER SUB-ASSEMBLY Install the water filler sub-assembly and water filler bracket with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the inlet radiator hose and No. 1 radiator hose to the radiator assembly with the 2 clamps. Connect the radiator cap hose to the water filler sub-assembly.
14. INSTALL RADIATOR COVER PLATE Install the radiator cover plate with the 6 clips.
15. INSTALL AIR CLEANER DUCT Install the air cleaner duct with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
16. INSTALL RADIATOR RESERVE TANK ASSEMBLY Install the radiator reserve tank assembly with the 2 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
17. CONNECT OUTLET RADIATOR HOSE See step 3
18. ADD ENGINE COOLANT See step 2
19. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [07/2013 - ] - Step 1»(ref-612352-S22062286662014042900000)
20. INSTALL NO. 1 ENGINE UNDER COVER . Refer to «INSTALLATION [07/2013 - ] - Step 10»(ref-612378-S21479833412014042900000)
21. INSTALL FRONT BUMPER COVER Refer to «INSTALLATION [07/2013 - ]»(ref-612392-S29542371062014042900000)
22. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Install the air cleaner case sub-assembly with the 3 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) Connect the air cleaner duct and air intake boot with the 2 hose clamps. Engage the clamp to connect the wire harness. Connect the mass air flow meter connector. Connect the hose clamp with the clamp.

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1. FAN NO. 1 RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.
2. FAN NO. 2 RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 4 Battery voltage is not applied between terminals 1 and 2 Below 1 ohms 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 4 Battery voltage is applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.
3. FAN NO. 3 RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.