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2AZ-FE Cooling: Diagnosis Scion xB II

Cooling System (Mechanical) 30 illustrations ~1766 words

ON-VEHICLE INSPECTION

HINT

It is normal for the cooling fan to sometimes rotate when the ignition switch is turned from ACC to ON.

Scheme 5

Scheme 5: ON-VEHICLE INSPECTION
Scheme 5: ON-VEHICLE INSPECTION

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURES (Below 94°C (201°F)) Turn the ignition switch ON with the A/C switch OFF. Check that the cooling fan stops. If it does not, check the cooling fan relays and engine coolant temperature sensor, and then check for disconnection of the connector or a wire break between the cooling fan relay and engine coolant temperature sensor. Disconnect the engine coolant temperature sensor connector. Check that the cooling fan rotates. If it does not, check the fuses, cooling fan relays, ECM and cooling fan, and then check for an open circuit between the cooling fan relay and engine coolant temperature sensor. Reconnect the engine coolant temperature sensor connector.
  2. CHECK COOLING FAN OPERATION AT HIGH TEMPERATURES (Above 96°C (205°F)) Start the engine, and then raise the coolant temperature to above 96°C (205°F). HINT: Coolant temperature is the value detected by the engine coolant temperature sensor on the cylinder head. Check that the A/C switch is OFF. Check that the cooling fan rotates. If it does not, check the engine coolant temperature sensor, cooling fan, harness and connector.

Scheme 8

Scheme 8: REPLACEMENT
Scheme 8: REPLACEMENT

Scheme 9

Scheme 9
Scheme 9
  1. DRAIN ENGINE COOLANT Loosen the radiator drain cock plug. HINT: Collect the coolant in a container and dispose of it according to the regulations in your area. Remove the radiator reserve tank cap. CAUTION: Do not remove the radiator reserve tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Loosen the cylinder block drain cock plug.
  2. ADD ENGINE COOLANT NOTE: Fill the coolant according to following process in order to bleed air surely, if you drain the coolant while repairing. Improper work may cause engine damage, because air may remain in the cooling system. Do not open the radiator cap when the engine and radiator are hot. Tighten the radiator drain cock plug by hand. Tighten the cylinder block drain cock plug. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Remove the radiator reserve tank cap, then fill TOYOTA Super Long Life Coolant up to "B" line of reserve tank. Standard capacity TRANSAXLE SPECIFICATION Transaxle Specified condition Manual transaxle 6.0 liter (6.3 US qts, 5.3 lmp. qts) Automatic transaxle 5.9 liter (6.2 US qts, 5.2 lmp. qts) HINT: TOYOTA vehicles are filled with TOYOTA Super Long Life Coolant at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). NOTE: Never use water as a substitute for engine coolant. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the "B" line, add TOYOTA Super Long Life Coolant to the B line. Bleed air from the cooling system. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes. HINT: The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose. CAUTION: When squeezing the radiator hose: Wear protective gloves. Be careful as the radiator hose is hot. Keep your hands away from the radiator fan. Run the engine intermittently (5 seconds run at 3000 rpm and 45 seconds idle) for 7 minutes or more, (repeat 8 cycles or more) Squeeze the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION: When squeezing the radiator hose: Wear protective gloves. Be careful as the radiator hose is hot. Keep your hands away from the radiator fan. After the engine cools down, check the coolant level is between "LOW" and "FULL" line. If the coolant level is below the LOW line, repeat all of the procedures above. If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.
  3. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-289752-S32327768382008070700000) )

Scheme 10

Scheme 10: COMPONENTS
Scheme 10: COMPONENTS

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12: REMOVAL
Scheme 12: REMOVAL

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
  2. REMOVE NO. 1 ENGINE UNDER COVER
  3. REMOVE REAR ENGINE UNDER COVER RH
  4. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-289752-S03290858042008070700000) )
  5. REMOVE FAN AND GENERATOR V BELT (See «REMOVAL»(ref-289749-S02597127822008070700000) )
  6. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(ref-289764-S13815299902008070700000) )
  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 ASSEMBLY Remove the crankshaft position sensor clamp from the water pump. Disconnect the crankshaft position sensor wire from the clamp bracket. Remove the 4 bolts, 2 nuts and clamp bracket. Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump. NOTE: Be careful not to damage the contact surfaces of the water pump and cylinder block.

Scheme 16

Scheme 16: INSPECTION
Scheme 16: INSPECTION
  1. INSPECT WATER PUMP ASSEMBLY Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump assembly. Turn the pulley, and then check that the water pump bearing moves smoothly without making a "click" noise. If it does not move smoothly, replace the water pump assembly.

Scheme 17

Scheme 17: INSTALLATION
Scheme 17: INSTALLATION

Scheme 18

Scheme 18
Scheme 18
  1. INSTALL WATER PUMP ASSEMBLY Remove any old seal packing material from the contact surface. Apply a continuous line of seal packing as shown in the illustration. Standard seal diameter: 2.2 to 2.5 mm (0.09 to 0.10 in.) Seal packing: Toyota Genuine Seal Parking Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. The parts must be set within 3 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 crankshaft position sensor wire onto the clamp bracket. Install the crankshaft position sensor clamp onto the water pump.
  2. 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)
  3. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-289764-S22659262012008070700000) )
  4. INSTALL FAN AND GENERATOR V BELT (See «INSTALLATION»(ref-289749-S00055167482008070700000) )
  5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  6. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-289752-S03290858042008070700000) )
  7. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-289752-S32327768382008070700000) )
  8. INSTALL REAR ENGINE UNDER COVER RH
  9. INSTALL NO. 1 ENGINE UNDER COVER

Scheme 19

Scheme 19: COMPONENTS
Scheme 19: COMPONENTS

Scheme 20

Scheme 20: REMOVAL
Scheme 20: REMOVAL
  1. REMOVE NO. 1 ENGINE UNDER COVER
  2. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-289752-S03290858042008070700000) )
  3. DISCONNECT OUTLET RADIATOR HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  4. REMOVE INLET WATER Remove the 2 nuts and disconnect the inlet water from the cylinder block.
  5. REMOVE THERMOSTAT Remove the gasket from the thermostat.

Scheme 21

Scheme 21: INSPECTION
Scheme 21: INSPECTION

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. Immerse the thermostat in water, and then gradually heat the water. Check the valve opening temperature of the thermostat. Standard valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Standard valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 77°C (171°F). If it is not fully closed, replace the thermostat.

Scheme 24

Scheme 24: INSTALLATION
Scheme 24: INSTALLATION
  1. 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.
  2. INSTALL INLET WATER Install the inlet water with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  3. CONNECT OUTLET RADIATOR HOSE (See «INSTALLATION»(ref-289752-S17907450142008070700000) )
  4. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-289752-S03290858042008070700000) )
  5. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-289752-S32327768382008070700000) )
  6. INSTALL NO. 1 ENGINE UNDER COVER

Scheme 25

Scheme 25: COMPONENTS
Scheme 25: COMPONENTS

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29: ON-VEHICLE INSPECTION
Scheme 29: ON-VEHICLE INSPECTION

Scheme 30

Scheme 30
Scheme 30
  1. INSPECT COOLING FAN MOTOR Disconnect the fan motor connector. Connect the battery and ammeter to the fan motor connector. Check that the fan rotates smoothly, and then check the reading on the ammeter. Standard current CURRENT SPECIFICATION Tester Connection Condition Specified Condition 1(+) - 2(-) At 20°C (68°F) 7.4 to 10.9 A HINT: Refer to the illustration for the indication mark location. If the result is not as specified, replace the cooling fan motor. Reconnect the fan motor connector.
  2. INSPECT NO. 2 COOLING FAN MOTOR Disconnect the No. 2 fan motor connector. Connect the battery and ammeter to the No. 2 fan motor connector. Check that the No. 2 fan rotates smoothly, and then check the reading on the ammeter. Standard current TESTER CONNECTION SPECIFICATION Tester Connection Condition Specified Condition 1(+) - 2(-) At 20°C (68°F) 5.7 to 7.7 A HINT: Refer to the illustration for the indication mark location. If the result is not as specified, replace the No. 2 cooling fan motor. Reconnect the No. 2 fan motor connector.

Scheme 31

Scheme 31: REMOVAL
Scheme 31: REMOVAL

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-289743-S36547954692008070700000) )
  2. REMOVE NO. 1 RADIATOR GRILLE GARNISH (See «REMOVAL»(ref-289771-S20374716602008070700000) )
  3. REMOVE RADIATOR GRILLE (See «REMOVAL»(ref-289771-S20374716602008070700000) )
  4. REMOVE FRONT BUMPER COVER (See «REMOVAL»(ref-289771-S20374716602008070700000) )
  5. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-289752-S03290858042008070700000) )
  6. REMOVE BATTERY (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  7. SEPARATE NO. 1 WATER HOSE CLAMP BRACKET (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  8. SEPARATE HOOD LOCK CONTROL CABLE ASSEMBLY (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  9. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  10. DISCONNECT INLET RADIATOR HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  11. DISCONNECT OUTLET RADIATOR HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  12. REMOVE RADIATOR SUPPORT CUSHION (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  13. REMOVE NO. 2 FAN SHROUD (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  14. SEPARATE DISCHARGE HOSE SUB-ASSEMBLY (See «REMOVAL»(ref-289743-S22988430552008070700000) )
  15. SEPARATE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (See «REMOVAL»(ref-289743-S22988430552008070700000) )
  16. REMOVE CONDENSER (See «REMOVAL»(ref-289743-S22988430552008070700000) )
  17. DISCONNECT NO. 1 WATER BY-PASS HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  18. REMOVE RADIATOR ASSEMBLY (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  19. REMOVE LOWER RADIATOR SUPPORT (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  20. REMOVE INLET RADIATOR HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  21. REMOVE OUTLET RADIATOR HOSE (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  22. REMOVE FAN SHROUD (See «REMOVAL»(ref-289752-S03883011382008070700000) )
  23. REMOVE NO. 2 FAN Remove the nut and No. 2 fan.
  24. REMOVE FAN Remove the nut and fan.
  25. REMOVE NO. 2 COOLING FAN MOTOR Separate the wire harness clamp. Remove the 3 bolts and No. 2 cooling fan motor.
  26. REMOVE COOLING FAN MOTOR Separate the wire harness clamp. Remove the 3 bolts and cooling fan motor.

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