Cooling: Removal & Installation Scion tC I

REPLACEMENT

Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZE SYSTEMS

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
6. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
7. REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and water pump pulley. SST 09960-10010 (09962-01000, 09963-00700)
8. REMOVE WATER PUMP ASSY Remove the clamp of the crankshaft position sensor from the water pump. Disconnect the wire of the crankshaft position sensor from the clamp bracket. Remove the 4 bolts, 2 nuts and clamp bracket. Using a screwdriver, pry between the water pump and cylinder block, then remove the water pump. NOTE: Be careful not to damage the contact surface of the water pump and cylinder block.
9. INSTALL WATER PUMP ASSY Remove any old seal packing material from the contact surface. Apply a continuous bead of seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. The parts must be set within 3 minutes and must be assembled within 15 minutes after applying seal packing. Otherwise, the material must be removed and reapplied. Install the water pump and clamp bracket with the 4 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Install the wire of the crankshaft position sensor onto the clamp bracket. Install the clamp of the crankshaft position sensor onto the water pump.
10. INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
11. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
12. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
13. ADD ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
14. INSTALL BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
15. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2AZ-FE)»(ref-224770-S17497212542006031100000) )
16. INSTALL ENGINE UNDER COVER RH
17. INSTALL FRONT FENDER APRON SEAL RH

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1. INSPECT WATER PUMP ASSY Visually check the drain hole coolant leakage. If leakage is found, replace the water pump. Turn the pulley, then check that the water pump bearing moves smoothly without making a click noise. If it dose not move smoothly, replace the water pump.

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1. DRAIN ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
2. REMOVE WATER INLET Remove the 2 nuts, then remove the water inlet from the cylinder block.
3. REMOVE THERMOSTAT
4. INSTALL THERMOSTAT Install a new gasket onto the thermostat. Install the thermostat with the jiggle valve upward. HINT: The jiggle valve may be set to within 10 on either side of the prescribed position.
5. INSTALL WATER INLET Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
6. ADD ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
7. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2AZ-FE)»(ref-224770-S17497212542006031100000) )

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Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZE SYSTEMS

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
3. REMOVE ENGINE UNDER COVER RH
4. DISCONNECT RADIATOR HOSE INLET
5. DISCONNECT RADIATOR HOSE OUTLET
6. DISCONNECT OIL COOLER INLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
7. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
8. REMOVE RADIATOR ASSY Disconnect the 2 cooling fan motor connectors. Disconnect the 2 clamps of the engine room main wire. Disconnect the radiator reserve tank hose. Remove the 2 bolts and 2 radiator support uppers, then remove the radiator from the vehicle.
9. REMOVE RADIATOR SUPPORT LOWER
10. REMOVE FAN SHROUD Remove the 2 bolts. Remove the 2 pawl fittings, then remove the fan shroud together with motor.
11. INSTALL FAN SHROUD Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
12. INSTALL RADIATOR SUPPORT LOWER
13. INSTALL RADIATOR ASSY Install the radiator with the 2 bolts and 2 radiator support uppers. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) Connect the radiator reserve tank hose. Connect the 2 clamps of the engine room main wire. Connect the 2 cooling fan motor connectors.
14. CONNECT OIL COOLER OUTLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
15. CONNECT OIL COOLER INLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
16. CONNECT RADIATOR HOSE OUTLET
17. CONNECT RADIATOR HOSE INLET
18. ADD ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
19. INSTALL BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
20. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2AZ-FE)»(ref-224770-S17497212542006031100000) )
21. INSTALL ENGINE UNDER COVER RH

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1. REMOVE RADIATOR DRAIN COCK PLUG Remove the drain cock plug. Remove the O-ring from the drain cock plug.
2. ASSEMBLE SST SST 09230-01010 (09231-01010, 09231-01030) Install the claw onto the overhaul handle by inserting it in the hole at part "A" as shown in the illustration. While gripping the handle, adjust dimension B to between 0.2 and 0.3 mm, using the stopper bolt. Dimension "B": 0.2 to 0.3 mm (0.008 to 0.012 in) NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
3. UNCAULK CORE PLATE Straighten the core plate by gripping it with SST until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01030)
4. REMOVE RADIATOR TANK UPPER Lightly tap the bracket of the radiator tank (or radiator tank pipe) with a soft-faced hammer to remove the radiator tank. Remove the O-ring.
5. REMOVE RADIATOR TANK LOWER HINT: Perform the same procedures as the radiator tank upper.
6. INSPECT RADIATOR CORE SUB-ASSY Check the core plate for damage. HINT: If the sides of the core plate groove are deformed, it is impossible to reassemble the radiator tank. Therefore, first correct any deformation using pliers or a similar tool. Water leakage will occur if the bottom of the core plate groove is damaged or dented. Repair or replace it if necessary. NOTE: The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator assembly must be replaced.
7. INSTALL RADIATOR TANK UPPER Check that there are no foreign objects in the core plate groove, then install a new O-ring without twisting it. HINT: To clean the core plate groove, lightly rub it with sandpaper without scratching it. Install the radiator tank without damaging the O-ring. Tap the core plate with a soft-faced hammer so that there is no gap between the core plate and radiator tank.
8. INSTALL RADIATOR TANK LOWER HINT: Perform the same procedures as the radiator tank upper.
9. ASSEMBLE SST SST 09230-01010 (09231-01010, 09231-01020) Install the punch assembly into the overhaul handle by inserting it in the hole at 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 "B": 8.4 mm (0.331 in.)
10. CAULK CORE PLATE Lightly press SST against the core plate in the order shown in the illustration. After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01020) HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs. Do not tap the sections shown in the illustration or the oil cooler using SST. Use pliers or a similar tool. Be careful not to damage the core plate. Check the core plate height (H) after completing the caulking. Plate height (H): 8.7 to 9.1 mm (0.343 to 0.358 in.) If the height is not as specified, readjust the stopper bolt of the handle, then caulk again.
11. INSTALL RADIATOR DRAIN COCK PLUG Install a new O-ring onto the drain cock plug. Install the drain cock plug.