Engine Cooling System (Mechanical): Diagnosis Toyota Echo I

INSPECTION

Note. Check the coolant level when the engine is cold.

1. Check engine coolant level at reservoir. The engine coolant level should be between the "LOW" and "FULL" line. If low, check for leaks and add "Toyota Long Life Coolant" or equivalent up to the "FULL" line.
2. Check engine coolant quality. Remove the 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. There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. Reinstall the radiator cap.

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1. Drain engine coolant. Remove the 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. Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug on the engine coolant drain union (on the right front of the cylinder block), and drain the coolant. Close the drain plugs. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) for engine
2. Fill engine coolant. Slowly fill the system with coolant. Use of improper coolants may damage the engine cooling system. Use "Toyota Long Life Coolant" or equivalent and mix it with plain water according to the manufacture directions. Use of the coolant which includes more than 50% [freezing protection down to -35°C (-31°F)] or 60% [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended, but not more than 70%. NOTE: Do not use an alcohol type coolant or plain water alone. The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: Install the radiator cap. Start the engine, and bleed the cooling system. Refill the engine coolant reservoir with coolant until it reaches "FULL" line.
3. Check for coolant leaks.
4. Check engine coolant specific gravity is correct.

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1. Drain engine coolant.
2. Remove drive belt (See page CH-2).
3. Remove water pump. Using SST, remove the 3 bolts and pump pulley. SST 09960-10010 (09962-01000, 09963-00600) Remove the 3 bolts, 2 nuts, water pump and gasket.

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1. Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump.
2. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.

If necessary, replace the water pump.

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1. Install water pump. Install the water pump and a new gasket with the 3 bolt and 2 nuts. Torque: 11.0 N.m (110 kgf.cm, 8 ft.lbf) Using SST, install the pump pulley with the 3 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N.m (150 kgf.cm, 11 ft.lbf)
2. Install drive belt (See page CH-2).
3. Fill with engine coolant.
4. Start engine and check for leaks.
5. Recheck engine coolant level.

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Inspect Fins For Blockage

If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.

Note. If the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fin, so keep the following injection distance. INJECTION DISTANCE SPECIFICATIONS Injection Pressure Injection Distance 2,942-4,903 kpa (30 - 50 kg/cm2' 427 - 711 psi) 300 mm (11.811 in) 4,903 - 7,845 kpa (50 - 80 kg/cm2' 711 - 1,138 psi) 500 mm (19.685 in) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components.

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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 contaminations, 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) below, keep the radiator cap tester at an angle of over 30° 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: 93-123 kPa (0.95 - 1.25 kgf/cm2,13.5 - 17.8 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm2,11.3 psi) NOTE: 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 137 kPa (1.4 kgf/cm2,19.9 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 electric cooling fan connector. Disconnect the horn 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 clips and radiator cover. Remove the 7 (w/o A/C) or 9 (w/ A/C) bolts and upper radiator supports. Remove the radiator assembly. Remove the 2 radiator support cushions and grommets.
4. Remove electric cooling fan from radiator.

Remove the 3 bolts and cooling fan assembly.

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1. Remove drain plug. Remove the drain plug. Remove the O-ring.
2. Remove water filter. Disconnect the No. 3 radiator hose from the radiator. Remove the 2 bolts and water filter.
3. Assemble SST. SST 09230-01010 Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the illustration. While gripping the handle, adjust the stopper bolts so that dimension "B" shown in the illustration is 0.2 - 0.3 mm (0.008-0.012 in.). NOTE: If this adjustment is not done the claw may be damaged.
4. Uncaulk lock plates. Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts. SST 09230-01010
5. 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.
6. A/T: 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.

Note. The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

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1. A/T: 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. 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. Assemble SST. SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in 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: 8.4 mm (0.331 in.)
4. 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 shown in the illustration cannot be staked with SST. Use wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates. Check the lock plate height (H) after completing the caulking. Plate height: 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 water filler. Install the water filler with the 2 bolts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) Connect the No. 3 radiator hose to the radiator.
6. Install drain plug. Install a new O-ring to the drain plug. Install the drain plug.
7. 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/cm2, 26 psi) Submerge the radiator in water. Inspect for leaks.

Note. On radiator with resin tank, 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.