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Engine Cooling System: Diagnosis Toyota Highlander I рестайлинг

Cooling System (Mechanical) 25 illustrations ~2817 words

ON-VEHICLE INSPECTION

HINT

The cooling fan may rotate when the ignition switch is turned from ACC to ON. This is normal.

  1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83°C (181°F)) Turn the ignition switch ON. Check that the cooling fan stops. If not, check the cooling fan relay and ECT sensor, and check for disconnected connector or wire breaks between the cooling fan relay and ECT sensor. Disconnect the ECT sensor connector. Check that the cooling fan rotates. If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the cooling fan relay and ECT Sensor. Reconnect ECT sensor connector.
  2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 90°C (194°F)) Start the engine, and raise ECT to above 90°C (194°F). Check that the cooling fan rotates. If not, replace the ECT sensor.
  3. INSPECT COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 5.2 to 8.2 A at 20°C (68°F) If not, replace the cooling fan. Reconnect the cooling fan connector.

Scheme 6

Scheme 6: INSPECTION
Scheme 6: INSPECTION

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. INSPECT RELAY (Marking: FAN NO. 1, FAN NO. 3) Measure the resistance of the relay. Standard: RELAY (MARKING: FAN NO. 1, FAN NO. 3) SPECIFIED CONDITIONS Tester Connection Specified Condition 3-5 10 kohm or higher 3-5 Below 1 ohm (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
  2. INSPECT RELAY (Making: FAN NO. 2) Measure the resistance of the relay. Standard: RELAY (MAKING: FAN NO. 2) SPECIFIED CONDITIONS Tester Connection Specified Condition 3-4 Below 1 ohm 3-5 10 kohm or higher 3-5 Below 1 ohm (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
  3. INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between terminals 1 and 2. Standard: ENGINE COOLANT TEMPERATURE SENSOR SPECIFIED CONDITIONS Condition Specified Condition Approximately 20°C (68°F) 2.29 to 2.6 kohm Approximately 80°C (176°F) 0.300 to 0.327 kohm If the result is not as specified, replace the sensor. NOTE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check, dry the sensor.

Scheme 9

Scheme 9: REPLACEMENT
Scheme 9: REPLACEMENT
  1. DRAIN ENGINE COOLANT Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Drain engine coolant by loosening the radiator drain plug and the engine's cylinder block drain cock plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. Tighten the cylinder block drain cock plug. Torque: 25 Nm (255 kgf cm, 18 ft lbf)
  2. ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: ENGINE COOLANT CAPACITY Item Specified Condition w/ Heater (front only) Standard 6.3 liters (6.7 US qts, 5.5 Imp. qts) Towing 7.1 liters (7.5 US qts, 6.2 Imp. qts) w/ Heater (front and rear) Standard 7.7 liters (8.1 US qts, 6.8 Imp. qts) Towing 8.5 liters (9.0 US qts, 7.5 Imp. qts) HINT: Use of improper coolants may damage the engine cooling system. Only use "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. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene-glycol concentration is approximately 50% and freezing temperature is -35°C (-95°F)). Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTE: Do not use plain water alone. Pour coolant into the radiator reservoir tank until the coolant reaches the full line. Install the radiator cap. Start the engine and run the engine for 10 seconds. Remove the radiator cap after 10 seconds. Pour coolant if the coolant level is lower. Repeat steps (d) to (f) until the coolant level remains the same from steps (d) to (f). HINT: Perform the procedures above before the engine warms up. A warmed up engine causes the thermostat valve to open, and the air inside the engine circulates between the radiator and the engine. Install the radiator cap. Warm up the engine until the thermostat valve begins to open. HINT: As the engine warms up, press the radiator inlet and outlet hoses several times by hand. Stop the engine and wait until the coolant cools down to the ambient temperature. If the coolant is below the full line, add coolant. Install the radiator cap and check the radiator reservoir tank coolant level. If it is below the full line, add coolant.
  3. CHECK FOR ENGINE COOLANT LEAKS Fill the radiator with coolant and attach a radiator cap tester. Pump it to 118 kPa (1.2 kgf/cm 2 ,17.1 psi) and check leakage.

Scheme 10

Scheme 10: REPLACEMENT
Scheme 10: REPLACEMENT

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14
  1. DRAIN ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
  2. REMOVE FRONT WHEEL RH
  3. REMOVE FRONT FENDER APRON SEAL RH
  4. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  5. REMOVE ENGINE MOUNTING STAY NO.2 RH (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  6. REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  7. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )
  8. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-226415-S08272782282006032800000) )
  9. REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and pump pulley. SST 09960-10010 (09962-01000,09963-00700) Disconnect the crankshaft position sensor wire harness clamp.
  10. REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump.
  11. INSTALL WATER PUMP ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the water pump and cylinder block. HINT: Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the water pump as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent HINT: Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.087 to 0.098 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube. Install the water pump and bracket with the 4 bolts and 2 nuts. Torque: 9.0 Nm (92 kgf cm, 80 in. Ibf) Connect the crankshaft position sensor wire harness clamp.
  12. INSTALL WATER PUMP PULLEY Using SST, install the pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  13. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-226415-S08272782282006032800000) )
  14. INSTALL AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )
  15. INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  16. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  17. INSTALL ENGINE MOUNTING STAY NO.2 RH (See «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  18. INSTALL FRONT FENDER APRON SEAL RH
  19. INSTALL FRONT WHEEL RH
  20. ADD ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
  21. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S29116418352006032800000) )

Scheme 15

Scheme 15: INSPECTION
Scheme 15: INSPECTION
  1. INSPECT WATER PUMP ASSY Visually check for drain hole coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump assy. Visually check the air holes for coolant leakage. If leakage is found, replace the water pump assy. if engine coolant has leaked onto the timing belt, replace the timing belt.

Scheme 16

Scheme 16: REPLACEMENT
Scheme 16: REPLACEMENT

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. DRAIN ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
  2. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )
  3. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-226415-S08272782282006032800000) )
  4. DISCONNECT RADIATOR HOSE INLET
  5. REMOVE WATER INLET Remove the 2 nuts and disconnect the water inlet from the cylinder block.
  6. REMOVE THERMOSTAT
  7. INSTALL THERMOSTAT Install a new gasket to the thermostat. Install the thermostat with the jiggle valve facing up. HINT: The jiggle valve may be set within 10° on either side of the prescribed position.
  8. INSTALL WATER INLET Install the water inlet with the 2 nuts, as shown in the illustration. Torque: 9.0 N.m (92 kgf cm, 80 in. Ibf)
  9. INSTALL RADIATOR HOSE INLET
  10. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-226415-S08272782282006032800000) )
  11. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )
  12. ADD ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
  13. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S29116418352006032800000) )

Scheme 19

Scheme 19: ON-VEHICLE CLEANING
Scheme 19: ON-VEHICLE CLEANING
  1. INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTE: If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: STEAM CLEANER PRESSURES Distance Steam Cleaner Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf/cm 2 , 427 to 711 psl) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm 2 , 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components.

Scheme 20

Scheme 20: COMPONENTS
Scheme 20: COMPONENTS

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

HINT

The cooling fan may rotate when the ignition switch is turned from ACC to ON. This is normal.

  1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURE (Below 83°C (181°F)) Turn the ignition switch ON. Check that the cooling fan stops. If not, check the cooling fan relay and ECT switches, and check for disconnected connectors and wire breaks between the cooling fan relay and ECT switches. Disconnect the ECT switch No. 1 connector. Connect the terminals on the ECT switch No. 1 connector. Check that the No. 1 cooling fan rotates at a high speed. If not, check the No. 1 cooling fan relay and No. 1 cooling fan. Reconnect the ECT switch No. 1 connector. Disconnect the ECT switch No. 2 connector. Check that the No. 1 and No. 2 cooling fans rotate at a low speed. If not, check the No. 2 cooling fan relay, No. 3 cooling fan relay and No. 2 cooling fan. Reconnect the ECT switch No. 2 connector.
  2. CHECK COOLING FAN Disconnect the cooling fan connector. Connect the battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.5 to 11.5 A at 20° (68°F) If not, replace the cooling fan. Reconnect the cooling fan connector.

Scheme 23

Scheme 23: INSPECTION
Scheme 23: INSPECTION

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. INSPECT RELAY (Marking: FAN NO. 1, FAN NO. 3) Check the resistance of the relay. Standard: RELAY (MARKING: FAN NO. 1, FAN NO. 3) RESISTANCE Tester Connection Specified Condition 3-5 10 kohm or higher 3-5 Below 1 ohm (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
  2. INSPECT RELAY (Making: FAN NO. 2) Check the resistance of the relay. Standard: RELAY (MAKING: FAN NO. 2) RESISTANCE Tester Connection Specified Condition 3-4 Below 1 ohm 3-5 10 kohm or higher 3-5 Below 1 ohm (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
  3. INSPECT ECT SWITCH Check the resistance. Standard: ECT SWITCH RESISTANCE (NO.1) Temperature Specified Condition Above 98°C (208°F) Below 1 ohm Below 88°C (190°F) 10 kohm or higher If the result is not as specified, replace the sensor. NOTE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check, dry the sensor.
  4. INSPECT ECT SWITCH Check the resistance. Standard: ECT SWITCH (NO.2) RESISTANCE Temperature Specified Condition Above 93°C (199°F) Below 1 ohm Below 83°C (181°F) 10 kohm or higher If the result is not as specified, replace the sensor. NOTE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check, dry the sensor.

Scheme 27

Scheme 27: REPLACEMENT
Scheme 27: REPLACEMENT
  1. DRAIN ENGINE COOLANT Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Drain engine coolant by loosening the radiator drain cock plug and the engine's cylinder block drain cock plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. Tighten the cylinder block drain cock plugs. Torque: 13 Nm (133 kgf cm, 10 ft lbf)
  2. ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: ENGINE COOLANT CAPACITY Item Specified Condition w/ heater (front only) Standard 9.4 liters (9.9 US qts, 8.3 Imp. qts) Towing 10.1 liters (10.7 US qts, 8.9 Imp. qts) w/ Rear heater (front and rear) Standard 10.7 liters (11.3 US qts, 9.4 Imp. qts) Towing 11.4 liters (12.0 US qts, 10.0 Imp. qts) HINT: Use of improper coolants may damage the engine cooling system. Only use "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. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethyleneglycol concentration is approximately 50% and freezing temperature is -35°C (-95°F)). Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTE: Do not use plain water alone. Pour coolant into the radiator reservoir tank until the coolant reaches the full line. Install the radiator cap. Warm up the engine. HINT: As the engine warms up, press the inlet and outlet radiator hoses several times by hand. Stop the engine and wait until the coolant cools down to the ambient temperature. Remove the radiator cap and check the coolant level inside the radiator. If the coolant level is below the full level, repeat steps (c) to (g) until the coolant level stays the same from step (c) to (g). Install the radiator cap and check the radiator reservoir tank coolant level. If it is below the full line, add coolant.
  3. CHECK FOR ENGINE COOLANT LEAKS Fill the radiator with coolant and attach a radiator cap tester. Pump it to 118 kPa (1.2 kgf/cm 2 , 17.1 psi) and check leakage.

Scheme 28

Scheme 28: REPLACEMENT
Scheme 28: REPLACEMENT

Scheme 29

Scheme 29
Scheme 29
  1. DRAIN ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
  2. REMOVE FRONT WHEEL RH
  3. REMOVE FRONT FENDER APRON SEAL RH
  4. REMOVE V BELT NO. 1 (See «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) )
  5. REMOVE VANE PUMP V BELT (See «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) )
  6. REMOVE ENGINE MOVING CONTROL ROD (See «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  7. REMOVE ENGINE MOUNTING STAY NO.2 RH (See «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  8. REMOVE GENERATOR BRACKET NO.2
  9. REMOVE CRANKSHAFT PULLEY (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  10. REMOVE TIMING BELT NO.1 COVER
  11. REMOVE TIMING BELT NO.2 COVER
  12. REMOVE ENGINE MOUNTING BRACKET RH
  13. REMOVE TIMING BELT GUIDE NO.2
  14. REMOVE TIMING BELT (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  15. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 Remove the bolt and timing belt idler.
  16. REMOVE CAMSHAFT TIMING PULLEY (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  17. REMOVE TIMING BELT NO.3 COVER
  18. REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts and water pump.
  19. INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8.0 N m (82 kgf cm, 71 in. Ibf)
  20. INSTALL TIMING BELT NO.3 COVER (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  21. INSTALL CAMSHAFT TIMING PULLEY (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  22. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 34 N m (347 kgf cm, 25 ft Ibf)
  23. INSPECT TIMING BELT (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  24. INSTALL TIMING BELT (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  25. INSTALL TIMING BELT TENSIONER ASSY (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  26. INSTALL TIMING BELT GUIDE NO.2 (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  27. INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N m (551 kgf cm, 40 ft Ibf)
  28. INSTALL TIMING BELT NO.2 COVER (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  29. INSTALL TIMING BELT NO.1 COVER (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  30. INSTALL CRANKSHAFT PULLEY (See «OVERHAUL»(ref-226410-S13885426382006032800000) )
  31. INSTALL GENERATOR BRACKET NO.2 Torque: 43 N m (438 kgf cm, 32 ft Ibf)
  32. INSTALL ENGINE MOUNTING STAY NO.2 RH (See «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  33. INSTALL ENGINE MOVING CONTROL ROD (See «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  34. INSTALL VANE PUMP V BELT (See «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) )
  35. INSTALL V BELT NO. 1 (See «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) )
  36. INSPECT DRIVE BELT TENSION (See «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) )
  37. ADD ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
  38. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S36470855222006032800000) )
  39. INSTALL FRONT WHEEL RH

Scheme 30

Scheme 30: INSPECTION
Scheme 30: INSPECTION
  1. INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump assy. Visually check the air holes for coolant leakage. If leakage is found, replace the water pump assy. if engine coolant has leaked onto the timing belt, replace the timing belt.

More articles — Engine Cooling System