Engine Cooling System: Other Toyota Corolla IX

ON-VEHICLE CLEANING

Using water or a steam cleaner, remove any mud or dirt from the radiator core.

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1. Remove radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
2. Inspect radiator cap. NOTE: If the radiator cap has contaminates, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps a and b , keep the tester at an angle of over 30 degrees above the horizontal. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push (3 seconds or more) NOTE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 seconds NOTE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 74 - 103 kPa (0.75 - 1.05 kgf/cm 2 , 10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm 2 , 8.5 psi) Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap.
3. Inspect cooling system for leaks. Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Pump it to 118 kPa (1.2 kgf/cm 2 , 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
4. Reinstall radiator cap.

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1. Drain engine coolant.
2. Remove engine under covers.
3. Remove radiator assembly. Disconnect the No. 1 electric cooling fan connector. Disconnect the No. 2 electric cooling fan connector. Disconnect the upper radiator hose. Disconnect the lower radiator hose. Disconnect the radiator reservoir hose. A/T: Disconnect the 2 oil cooler hoses. Remove the 2 bolts and upper radiator supports. Remove the radiator assembly. Remove the 2 lower radiator supports.
4. Remove electric cooling fan from radiator. Remove the 5 bolts and cooling fan assembly.

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1. Remove drain plug. Remove the drain plug. Remove the O-ring.
2. DENSO Made: Assemble SST. SST 09230-01010 Install the claw to the overhaul handle, inserting it in the hole in part "A" (Scheme 19) While gripping the handle, adjust the stopper bolts so that dimension "B" (Scheme 19)is 0.2 - 0.3 mm (0.008 - 0.012 in.). CAUTION: If this adjustment is not done the claw may be damaged.
3. DENSO Made: Uncaulk lock plates. Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts. SST 09230-01010
4. DENSO Made: Remove tanks and O-rings Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove the tank and the O-ring.
5. A/T (DENSO Made): Remove oil cooler from lower tank. Remove the 2 nuts and 2 plate washers. Remove the oil cooler and 2 O-rings.

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Note. If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged.

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1. A/T (DENSO Made): Install oil cooler to lower tank. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank. Install the 2 plate washers and 2 nuts. Torque: 8.34 N.m (85 kgf.cm, 74 in..lbf)
2. DENSO Made: Install new O-rings and tanks. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. NOTE: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. Install the tank without damaging the O-ring. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.
3. DENSO Made: Assemble SST. SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" (Scheme 27) While gripping the handle, adjust the stopper bolt so that dimension "B" is (Scheme 27) Dimension: 8.4 mm (0.331 in.)
4. DENSO Made: Caulk lock plate. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, stopped by the stopped plate. SST 09230-01010 NOTE: Do not stake the areas protruding around the pipes, brackets or tank rids. The points (Scheme 30)cannot be staked with SST. Wrap vinyl tape around the tip of a pair pliers or similar object and be careful not to damage the core plates. Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 - 7.80 mm (0.2913 - 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
5. Install drain plug. Install a new O-ring to the drain plug. Install the drain plug.
6. Inspect for water leaks. Tighten the drain plug. Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm 2, 26 psi) Submerge the radiator in water. Inspect for leaks. NOTE: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. therefore, before doing the water leak test, first swish the radiator around in the water until all bubbles disappear.

Scheme 34

1. Install electric cooling fan to radiator. Install the cooling fan with the 5 bolts. Torque: 6 N.m (60 kgf.cm, 53 in..lbf)
2. Install radiator assembly. Install the 2 lower radiator supports to the radiator. Attach the 2 lower radiator supports on the radiator to the body brackets. Install the 2 upper radiator supports with the 2 bolts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) NOTE: After installation, check that the rubber cushion (A), in (Scheme 34), of the support is not depressed. w/ A/C: Install the A/C condenser with the 4 bolts. Connect the upper radiator hose. Connect the lower radiator hose. Connect the radiator reservoir hose. A/T: Connect the 2 oil cooler hoses to oil cooler pipes. Connect the No. 1 electric cooling fan connector. Connect the No. 2 electric cooling fan connector.
3. Install engine under covers.
4. Fill with engine coolant.
5. Start engine and check for coolant leaks.