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Engine Cooling System: Diagnosis Toyota Corolla IX рестайлинг

Cooling Fan 16 illustrations ~1356 words

ON-VEHICLE INSPECTION

HINT

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

  1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURES (Below 83°C (181°F)) Turn the ignition switch to ON with the A/C switch OFF. Check that the cooling fan stops.
  2. CHECK COOLING FAN OPERATION AT HIGH TEMPERATURES (Above 100 C (212 F)) Start the engine, then raise coolant temperature to above 100°C (212° 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.
  3. INSPECT FAN Disconnect the fan connector. Connect the battery and ammeter to the fan connector. Check that the fan rotates smoothly, then check the reading on the ammeter. Standard amperage: 8.4 to 11.2 A at 20°C (68°F) If the amperage is not as specified, replace the cooling fan motor. Reconnect the fan connector.

Scheme 18

Scheme 18: INSPECTION
Scheme 18: INSPECTION

Scheme 19

Scheme 19
Scheme 19
  1. COOLING FAN RELAY Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard: TESTER CONNECTION - SPECIFIED CONDITION Tester Connection Specified Condition 3-5 10k ohms or higher 3-5 Below 1 ohms (Apply battery voltage to terminals 1 and 2) If the resistance is not as specified, replace the relay.
  2. COOLING FAN RELAY NO. 2 Check the resistance. Using an ohmmeter, measure the resistance between each terminal. Standard: TESTER CONNECTION - SPECIFIED CONDITION Tester Connection Specified Condition 3-4 Below 1ohms 3-4 10kohms or higher (Apply battery voltage to terminals 1 and 2) 3-5 10kohms or higher 3-5 Below 1 ohms (Apply battery voltage to terminals 1 and 2) If the resistance is not as specified, replace the relay.
  3. COOLING FAN RESISTOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 1.17 to 1.43 ohms at 20°C (68°F)

Scheme 20

Scheme 20: REPLACEMENT
Scheme 20: REPLACEMENT
  1. DRAIN ENGINE COOLANT CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. Loosen the radiator drain plug (lower side) and water drain plug, then drain the coolant. Remove the radiator cap. Close the radiator drain plug (lower side). Tighten the water drain plug. Torque: 12.7 N.m (129 kgf.cm, 9 ft.lbf)
  2. ADD ENGINE COOLANT Fill the radiator with coolant from the fill port. NOTE: Do not use an alcohol type coolant or plain water alone. Capacity: 6.7 liters (7.1 US qts, 5.9 Imp. qts) HINT: Use of improper coolants may damage the engine cooling system. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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). Toyota Super Long Life Coolant is premixed with 50% coolant and 50% deionized water. This coolant provides protection down to about -35°C (-31°F). Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant. Install the radiator cap securely. Fill the radiator reserve tank with coolant. Warm up the engine until the coolant full. Warm up the engine until the fan starts running with A/C, heater and defroster off. Stop the engine and wait until the coolant cools down, (h) Remove the radiator cap and check the coolant level. If the coolant level is below the full level, perform the steps from (a) through (f) and repeat the operation until the coolant level stays the full level, When the coolant level stops going down, adjust the amount of the coolant in the radiator reserve tank.
  3. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2ZZ-GE)»(ref-225496-S27954524102006031900000) )

Scheme 21

Scheme 21: REPLACEMENT
Scheme 21: REPLACEMENT

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. DISCONNECT BATTERY NEGATIVE TERMINAL
  2. DRAIN COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  3. REMOVE ENGINE UNDER COVER RH
  4. REMOVE CYLINDER HEAD COVER NO. 2 Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
  5. REMOVE WIRE HARNESS PROTECTOR (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  6. SEPARATE SUCTION HOSE SUB-ASSY (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  7. REMOVE AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
  8. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  9. REMOVE GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  10. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  11. REMOVE WATER PUMP PULLEY Using SST, remove the water pump pulley. SST 09960-10010 (09962-01000, 09963-00600)
  12. REMOVE WATER PUMP ASSY Remove the 6 bolts and water pump. Remove the O-ring from the timing chain cover.
  13. INSTALL WATER PUMP ASSY Place a new O-ring on the timing chain cover. Install the water pump with the 6 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in lbf) HINT: Each bolt length is indicated in the table. BOLT LENGTH SPECIFICATION Bolt A 35 mm (1.38 in.) Bolt B 28 mm (1.10 in.)
  14. INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
  15. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  16. INSTALL GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  17. INSTALL AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
  18. INSTALL SUCTION HOSE SUB-ASSY Torque: 9.8 N.m (100 kgf.cm, 87 in. lbf)
  19. INSTALL CYLINDER HEAD COVER NO. 2 Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf)
  20. CONNECT BATTERY NEGATIVE TERMINAL
  21. ADD COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  22. CHECK FOR ENGINE COOLANT LEAKAGE (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )

Scheme 25

Scheme 25: INSPECTION
Scheme 25: INSPECTION
  1. INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Check the area of the water pump assembly indicated in (Scheme 25) for traces of coolant leakage. If leakage is found, replace the water pump.

Scheme 26

Scheme 26: REPLACEMENT
Scheme 26: REPLACEMENT
  1. DISCONNECT BATTERY NEGATIVE TERMINAL
  2. DRAIN COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  3. REMOVE ENGINE UNDER COVER RH
  4. REMOVE CYLINDER HEAD COVER NO. 2 Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
  5. REMOVE WIRE HARNESS PROTECTOR (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  6. SEPARATE SUCTION HOSE SUB-ASSY (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  7. REMOVE AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
  8. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2ZZ-GE)»(ref-225494-S06918874152006031900000) )
  9. REMOVE GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  10. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  11. REMOVE WATER INLET
  12. REMOVE THERMOSTAT
  13. INSTALL THERMOSTAT Install a new gasket onto the thermostat. Install the thermostat with the jiggle valve upward (Scheme 26)
  14. INSTALL WATER INLET Torque: 10 N.m (102 kgf.cm, 7ft. lbf)
  15. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  16. INSTALL GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
  17. INSTALL AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
  18. INSTALL SUCTION HOSE SUB-ASSY Torque: 9.8 N.m (100 kgf.cm, 87 in. lbf)
  19. INSTALL CYLINDER HEAD COVER NO. 2 Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf)
  20. CONNECT BATTERY NEGATIVE TERMINAL
  21. ADD COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  22. CHECK FOR ENGINE COOLANT LEAKAGE (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )

Scheme 27

Scheme 27: REPLACEMENT
Scheme 27: REPLACEMENT

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33
  1. DISCONNECT BATTERY NEGATIVE TERMINAL
  2. DRAIN COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  3. REMOVE AIR PUMP OUTLET PIPE Disconnect the air hose No. 6. Disconnect the air hose No. 5. Remove the 2 bolts and air pump outlet pipe.
  4. DISCONNECT RADIATOR HOSE INLET
  5. DISCONNECT RADIATOR HOSE OUTLET
  6. REMOVE RADIATOR W/FAN Disconnect the fan motor connector. Disconnect the 2 clamps for the wire harness from the fan shroud. Remove the 2 bolts and 2 radiator support uppers. Remove the radiator together with the fan. Remove the 2 radiator support lowers.
  7. REMOVE RADIATOR ASSY Disconnect the radiator reserve tank hose. Remove the 2 bolts and fan shroud.
  8. INSTALL RADIATOR ASSY Install the fan shroud with the 2 bolts. Torque: 6.0 N.m (61 kgf.cm, 53 in. lbf) Connect the radiator reserve tank hose.
  9. INSTALL RADIATOR W/FAN Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
  10. INSTALL AIR PUMP OUTLET PIPE Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf)
  11. CONNECT BATTERY NEGATIVE TERMINAL
  12. ADD COOLANT (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )
  13. CHECK FOR ENGINE COOLANT LEAKAGE (See «ENGINE COOLANT (2ZZ-GE)»(ref-225496-S38931962692006031900000) )

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