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Engine Cooling System (2GR-FE) (Except Hybrid): Overview Toyota Highlander II

Cooling Fan 68 illustrations ~4837 words

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Scheme 1: ON-VEHICLE INSPECTION
Scheme 1: ON-VEHICLE INSPECTION
  1. INSPECT FOR COOLANT LEAK 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. NOTE: Before performing each inspection, turn the A/C switch off. Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm 2 , 17 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator and. water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
  2. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR Check that the engine coolant level is between the LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "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 to the FULL line. NOTE: Do not substitute plain water for engine coolant.
  3. INSPECT ENGINE COOLANT QUALITY 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. Check if there are any excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. Install the radiator cap.

DESCRIPTION

The ECM calculates an appropriate cooling fan speed based on the engine coolant temperature, air conditioning switch condition, refrigerant pressure, engine speed, and vehicle speed and sends the signals to the cooling fan ECU to regulate the cooling fan. The cooling fan ECU controls the cooling fan speed based on the duty ratio signal sent from the ECM. By basing its control on the operating conditions, the ECM can control the fan speed optimally using the cooling fan ECU, achieving both high cooling performance and quietness. The cooling fan speed is determined based on engine coolant temperature, air conditioner operating conditions, engine speed, and vehicle speed.

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Scheme 2: INSPECTION PROCEDURE
Scheme 2: INSPECTION PROCEDURE

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  1. PERFORM ACTIVE TEST BY TECHSTREAM (CONTROL THE COOLING FAN) Connect Techstream to the DLC3. Turn the ignition switch on (IG). Enter the following menus: Powertrain/Engine and ECT/Active Test/Control the Cooling Fan. Check the operation of the cooling fan while operating it using Techstream. OK: The cooling fan rotates. NG: Go to step 2 OK: REPLACE ECM (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#engine-control-system-2gr-fe-except-hybrid) )
  2. CHECK HARNESS AND CONNECTOR (ECM - COOLING FAN ECU) Disconnect the D31 connector from the ECM. Disconnect the cooling fan ECU connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition D31-14 (RFC) - A9-2 (SI) Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  3. INSPECT NO. 1 COOLING FAN MOTOR Disconnect the No. 1 cooling fan motor connector. Connect the battery positive terminal to terminal 2 of the cooling fan connector, and connect the battery negative terminal to terminal 1 of the No. 1 cooling fan motor connector. OK: The No. 1 cooling fan rotates. NG: REPLACE NO. 1 COOLING FAN MOTOR (See «REMOVAL»(ref-290672-S38531203072008071700000) ) OK: Go to next step
  4. INSPECT NO. 2 COOLING FAN MOTOR Disconnect the No. 2 cooling fan motor connector. Connect the battery positive terminal to terminal 2 of the cooling fan connector, and connect the battery negative terminal to terminal 1 of the No. 2 cooling fan motor connector. OK: The No. 2 cooling fan rotates. NG: REPLACE NO. 2 COOLING FAN MOTOR (See «REMOVAL»(ref-290672-S38531203072008071700000) ) OK: Go to next step
  5. CHECK COOLING FAN ECU (POWER SOURCE) Disconnect the cooling fan ECU connector. Turn the ignition switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION TABLE Tester Connection Switch Condition Specified Condition A9-3 (+B1) - A9-1 (E1) Ignition switch on (IG) 11 to 14 V NG: Go to step 6 OK: REPLACE COOLING FAN ECU (See «REMOVAL»(ref-290672-S10185919302008071700000) )
  6. CHECK HARNESS AND CONNECTOR (COOLING FAN ECU - BODY GROUND) Disconnect the cooling fan ECU connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition A9-1 (E1) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  7. INSPECT FAN MAIN RELAY Remove the FAN MAIN relay from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Apply battery voltage between terminals 1 and 2 Below 1 ohms NG: REPLACE FAN MAIN RELAY OK: Go to next step
  8. CHECK HARNESS AND CONNECTOR (COOLING FAN ECU - FAN MAIN RELAY) Disconnect the cooling fan ECU connector. Remove the FAN MAIN relay from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition A9-3 (+B1) - 5 (FAN MAIN relay) Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  9. CHECK HARNESS AND CONNECTOR (FAN MAIN RELAY - BODY GROUND) Remove the FAN MAIN relay from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 2 (FAN MAIN relay) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  10. CHECK HARNESS AND CONNECTOR (FAN MAIN RELAY - FAN MAIN FUSE) Remove the FAN MAIN relay from the engine room relay block and junction block. Remove the fusible link block assembly from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 3 (FAN MAIN relay) - 1 (FAN MAIN fuse) Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  11. INSPECT FUSIBLE LINK BLOCK ASSEMBLY (FAN MAIN FUSE) Remove the fusible link block assembly from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 1 - 2 (FAN MAIN fuse) Always Below 1 ohms NG: REPLACE FUSIBLE LINK BLOCK ASSEMBLY OK: Go to next step
  12. CHECK FUSE (EFI MAIN) Remove the EFI MAIN fuse from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition EFI MAIN fuse Always Below 1 ohms NG: REPLACE FUSE OK: Go to next step
  13. CHECK HARNESS AND CONNECTOR (EFI MAIN FUSE - ENGINE ROOM JUNCTION BLOCK ASSEMBLY) Remove the EFI MAIN fuse from the engine room relay block and junction block. Remove the engine room junction block assembly from the engine room relay block and junction block. Disconnect the 2E connector from the engine room junction block assembly. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 2 (EFI MAIN fuse) - 2E-12 Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  14. CHECK HARNESS AND CONNECTOR (FAN MAIN RELAY - ENGINE ROOM JUNCTION BLOCK ASSEMBLY) Remove the FAN MAIN relay from the engine room relay block and junction block. Remove the engine room junction block assembly from the engine room relay block and junction block. Disconnect the 2E connector from the engine room junction block assembly. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 1 (FAN MAIN relay) - 2E-7 Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  15. CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BLOCK ASSEMBLY - BODY GROUND) Remove the engine room junction block assembly from the engine room relay block and junction block. Disconnect the 2D and 2E connectors from the engine room junction block assembly. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 2D-8 - Body ground Always Below 1 ohms 2E-10 - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  16. CHECK HARNESS AND CONNECTOR (ECM - ENGINE ROOM JUNCTION BLOCK ASSEMBLY) Disconnect the D31 connector from the ECM. Remove the engine room junction block assembly from the engine room relay block and junction block. Disconnect the 2E connector from the engine room junction block assembly. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition D31-8 (MREL) - 2E-9 Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  17. INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (EFI RELAY) Remove the engine room junction block assembly from the engine room relay block and junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION TABLE Tester Connection Condition Specified Condition 2E-12 - 2E-7 Battery voltage is not applied between terminals 2E-9 and 2E-10 10 kohms or higher 2E-12 - 2E-7 Apply battery voltage between terminals 2E-9 and 2E-10 Below 1 ohms NOTE: While using the battery for the inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. NG: REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#engine-control-system-2gr-fe-except-hybrid) ) OK: REPLACE ECM (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#engine-control-system-2gr-fe-except-hybrid) )

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Scheme 21: REPLACEMENT
Scheme 21: REPLACEMENT

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  1. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  2. REMOVE ENGINE UNDER COVER ASSEMBLY (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  3. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  4. 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 cap sub-assembly from the radiator assembly. NOTE: Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Loosen the 2 cylinder block drain cock plugs.
  5. ADD ENGINE COOLANT Tighten the radiator drain cock plug by hand. Tighten the 2 cylinder block drain cock plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for cylinder block drain cock plugs Loosen the air drain cock plug from the water inlet housing. Loosen the air drain plug at the top of the radiator 3 or 4 turns. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug to the water inlet housing. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for air drain cock plug Continue to add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the radiator air drain hole. Then close the air drain plug at the top of the radiator. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) for air drain plug HINT: If the coolant level at the radiator inlet opening drops after squeezing the No. 1 and No. 2 radiator hoses, add coolant. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Standard capacity w/o Trailer Towing System SPECIFIED CONDITION TABLE Condition Specified Condition w/ Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts) w/o Rear Heater 8.8 liters (9.3 US qts, 7.7 Imp. qts) w/ Trailer Towing System SPECIFIED CONDITION TABLE Condition Specified Condition w/ Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts) w/o Rear Heater 9.5 liters (10.1 US qts, 8.4 Imp. qts) HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC 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). Contact your TOYOTA dealer for further details. NOTE: Never use water as a substitute for engine coolant. Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. Bleed air from the cooling system. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. HINT: The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose. Maintain the engine speed at 2500 to 3000 rpm. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION: When squeezing the radiator hoses: Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the radiator fan. NOTE: Make sure that the radiator reservoir still has some coolant in it. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool. If there is not enough coolant, the engine may overheat or be seriously damaged. If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line. Stop the engine and wait until the engine coolant cools down. Add engine coolant to the FULL line on the radiator reservoir.
  6. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-290672-S33614443232008071700000) )
  7. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  8. INSTALL ENGINE UNDER COVER ASSEMBLY (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  9. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-290671-S10481115252008071700000) )

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Scheme 23: COMPONENTS
Scheme 23: COMPONENTS

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Scheme 25: ON-VEHICLE INSPECTION
Scheme 25: ON-VEHICLE INSPECTION
  1. REMOVE FRONT WHEEL RH
  2. REMOVE ENGINE UNDER COVER ASSEMBLY (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  3. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  4. REMOVE FRONT FENDER MOLDING SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side (See «REMOVAL»(ref-290671-S10502677982008071700000) ).
  5. REMOVE FRONT FENDER LINER RH (See «REMOVAL»(ref-290677-S17393885912008071700000) )
  6. REMOVE FRONT FENDER APRON SEAL RH (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  7. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-290671-S09458924842008071700000) )
  8. INSPECT WATER PUMP ASSEMBLY Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump assembly. Make sure that there are no drops of coolant on the water pump housing. If necessary, replace the water pump assembly.
  9. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-290671-S18614036302008071700000) )
  10. INSTALL FRONT FENDER APRON SEAL RH (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  11. INSTALL FRONT FENDER LINER RH (See «INSTALLATION»(ref-290677-S01035218362008071700000) )
  12. INSTALL FRONT FENDER MOLDING SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side (See «INSTALLATION»(ref-290671-S10481115252008071700000) ).
  13. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  14. INSTALL ENGINE UNDER COVER ASSEMBLY (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  15. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

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Scheme 26: REMOVAL
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  1. REMOVE THE V-BANK COVER SUB-ASSEMBLY
  2. DRAIN ENGINE COOLANT. Refer to «REPLACEMENT»(ref-290672-S25283065902008071700000).
  3. REMOVE V-RIBBED BELT Using SST, release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner assembly. SST: 09961-00950 While turning the V-ribbed belt tensioner assembly counterclockwise, align with its holes, and then insert the 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner assembly.
  4. DISCONNECT ENGINE WIRE Remove the 3 bolts and disconnect the engine wire.
  5. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
  6. REMOVE ENGINE MOVING CONTROL ROD Remove the 3 bolts and engine moving control rod.
  7. DISCONNECT NO. 2 RADIATOR HOSE Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 2 radiator hose from the water inlet.
  8. REMOVE REAR ENGINE MOUNTING INSULATOR Remove the 2 hole plugs. Remove the 2 nuts and transverse engine mounting insulator.
  9. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR Remove the hole plug. Remove the 3 nuts.
  10. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR NO. 2 Remove the 2 hole plugs. Remove the 3 nuts.
  11. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH Remove the 4 bolts. Using SST, remove the bolt (A). SST: 09249-37010 Using SST, remove the bolt (B). SST: 09961-00950 Place a wooden block between a jack and the engine. NOTICE: Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan. Jack up the engine slightly, and remove the 2 bolts and No. 1 front engine mounting bracket LH. HINT: Do not jack up the engine excessively. HINT: Lift the engine so that bolt A passes above the No. 1 cooler refrigerant suction pipe. Lower the engine, and remove the jack. NOTICE: When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly.
  12. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, idler pulley cover plate, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly. HINT: Plate diameter: Idler pulley cover plate: 33.6 mm (1.32 in.) No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
  13. REMOVE V-RIBBED BELT TENSIONER PULLEY Remove the 5 mm bi-hexagon wrench. Using SST, remove the bolt, dust shield and V-ribbed belt tensioner pulley. SST: 09960-10010 NOTICE: *Do not turn the bolt labeled "L" counterclockwise. *Store the V-ribbed belt tensioner pulley so that the bearing does not get damaged.
  14. SEPARATE WATER PUMP PULLEY Using SST, hold the water pump pulley. SST: 09960-10010 09962-01000 09963-00700 Remove the 4 bolts and water pump pulley. HINT: There is not enough clearance to completely remove the water pump pulley from the water pump shaft. Remove the water pump pulley together with the water pump.
  15. REMOVE WATER INLET HOUSING Disconnect the water hose. Remove the 2 bolts, nut and water inlet housing. Remove the water inlet housing gasket and water outlet pipe O-ring.
  16. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021
  17. REMOVE WATER PUMP ASSEMBLY Remove the 16 bolts, water pump assembly and water pump gasket.

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Scheme 48: INSTALLATION
Scheme 48: INSTALLATION

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  1. INSTALL WATER PUMP ASSEMBLY Install a new water pump gasket and the water pump assembly with the 16 bolts. Bolt A Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) Bolts B and C Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE: Make sure that there is no oil on the threads of bolts A. Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  2. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
  3. INSTALL WATER INLET HOUSING Install a new water inlet housing gasket and water outlet pipe O-ring. Install the water inlet housing with the 2 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful not to allow the O-ring to get caught between the parts. Connect the water hose.
  4. INSTALL WATER PUMP PULLEY Temporarily install the water pump pulley with the 4 bolts. Using SST, hold the water pump pulley. SST: 09960-10010 09962-01000 09963-00700 Tighten the 4 bolts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  5. INSTALL V-RIBBED BELT TENSIONER PULLEY Install the V-ribbed belt tensioner pulley and dust shield with the bolt. SST: 09961-00950 without SST - Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) with SST - Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) NOTICE: Be careful when tightening the bolt because its thread is left-handed. Install the dust shield in the direction shown in the illustration. Failure to do so may cause looseness. Make sure to use the removed bolt. (Do not use another bolt even if it is the same size.) Install the 5 mm bi-hexagon wrench.
  6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley cover plate, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly with the bolt. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) HINT: Plate diameter: Idler pulley cover plate: 33.6 mm (1.32 in.) No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
  7. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH Place a wooden block between a jack and the engine. NOTICE: Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan. Jack up the engine slightly, and temporarily install the No. 1 front engine mounting bracket LH with the 2 bolts. HINT: Do not jack up the engine excessively. HINT: Lift the engine so that bolt A passes above the No. 1 cooler refrigerant suction pipe. Lower the engine, and remove the jack. NOTICE: When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly. Install the 4 bolts. Torque: 54 N.m (551 kgf.cm, 40ft.lbf) Using SST, tighten the bolt (A). SST: 09249-37010 without SST - Torque: 54 N.m (551 kgf.cm, 40ft.lbf) with SST - Torque: 39 N.m (398 kgf.cm, 29ft.lbf) HINT: Use a torque wrench with a fulcrum length of 26 cm (10.24 in.). The effective length of SST (09249-37010) is 10 cm (3.9 in.). Using SST, tighten the bolt (B). SST: 09249-37010 without SST - Torque: 54 N.m (551 kgf.cm, 40ft.lbf) with SST - Torque: 39 N.m (398 kgf.cm, 29ft.lbf) HINT: Use a torque wrench with a fulcrum length of 26 cm (10.24 in.). The effective length of SST (09249-37010) is 10 cm (3.9 in.).
  8. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR NO. 2 Install the 3 nuts. Torque: 87 N.m (888 kgf.cm, 65ft.lbf) Install the 2 hole plugs.
  9. CONNECT TRANSVERSE ENGINE MOUNTING INSULATOR Install the 3 nuts. Torque: 52 N.m (531 kgf.cm, 39ft.lbf) Install the hole plug.
  10. CONNECT REAR ENGINE MOUNTING INSULATOR Install the 2 nuts and transverse engine mounting insulator. Torque: 52 N.m (531 kgf.cm, 39ft.lbf) Install the 2 hole plugs.
  11. CONNECT NO. 2 RADIATOR HOSE Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 radiator hose to the water inlet.
  12. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the bolt, 2 nuts and No. 2 engine mounting stay RH.
  13. INSTALL ENGINE MOVING CONTROL ROD Temporarily install the engine moving control rod with the 3 bolts. First install bolts A, and then bolt B. Torque: 38 N.m (387 kgf.cm, 28ft.lbf)
  14. CONNECT ENGINE WIRE Install the 3 bolts and disconnect the engine wire.
  15. INSTALL V-RIBBED BELT Install the V-ribbed belt. SST: 09961-00950 Using SST, turn the V-ribbed belt tensioner assembly counterclockwise and remove the bar. If it is difficult to install the V-ribbed belt, perform the following procedure: Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, and put the V-ribbed belt on the V-ribbed tensioner assembly pulley. NOTICE: Put the backside of the V-ribbed belt on the V-ribbed belt tensioner assembly pulley and No. 2 idler pulley sub-assembly. Check that the V-ribbed belt is properly set to each pulley. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crankshaft pulley by hand.
  16. ADD ENGINE COOLANT. Refer to «REPLACEMENT»(ref-290672-S25283065902008071700000).
  17. INSTALL THE V-BANK COVER SUB-ASSEMBLY

Scheme 53

Scheme 53: COMPONENTS
Scheme 53: COMPONENTS

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55: REMOVAL
Scheme 55: REMOVAL

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57
  1. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  2. REMOVE ENGINE UNDER COVER ASSEMBLY (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  3. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  4. REMOVE FRONT WHEEL RH
  5. REMOVE FRONT FENDER MOLDING SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side (See «REMOVAL»(ref-290671-S10502677982008071700000) ).
  6. REMOVE FRONT FENDER LINER RH (See «REMOVAL»(ref-290677-S17393885912008071700000) )
  7. REMOVE FRONT FENDER APRON SEAL RH (See «REMOVAL»(ref-290671-S10502677982008071700000) )
  8. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-290672-S25283065902008071700000)
  9. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-290671-S09458924842008071700000) )
  10. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose from the engine.
  11. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, idler pulley cover plate and idler pulley sub-assembly.
  12. REMOVE WATER INLET Remove the 2 nuts and water inlet.
  13. REMOVE THERMOSTAT Remove the thermostat from the water inlet housing Remove the gasket from the thermostat.

Scheme 58

Scheme 58: INSPECTION
Scheme 58: INSPECTION

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60
  1. INSPECT THERMOSTAT Inspect the thermostat. HINT: The valve opening temperature is inscribed on the thermostat. Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. 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. 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 40°C (104°F)). If it is not fully closed, replace the thermostat.

Scheme 61

Scheme 61: INSTALLATION
Scheme 61: INSTALLATION
  1. 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.
  2. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley cover plate and idler pulley sub-assembly with the bolt. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  4. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose to the engine.
  5. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-290671-S18614036302008071700000) )
  6. INSTALL FRONT FENDER APRON SEAL RH (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  7. INSTALL FRONT FENDER LINER RH (See «INSTALLATION»(ref-290677-S01035218362008071700000) )
  8. INSTALL FRONT FENDER MOLDING SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side (See «INSTALLATION»(ref-290671-S10481115252008071700000) ).
  9. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
  10. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-290672-S25283065902008071700000)
  11. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-290672-S33614443232008071700000) )
  12. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  13. INSTALL ENGINE UNDER COVER ASSEMBLY (See «INSTALLATION»(ref-290671-S10481115252008071700000) )
  14. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-290671-S10481115252008071700000) )

Scheme 62

Scheme 62: COMPONENTS
Scheme 62: COMPONENTS

Scheme 63

Scheme 63: ON-VEHICLE INSPECTION
Scheme 63: ON-VEHICLE INSPECTION

Scheme 64

Scheme 64
Scheme 64
  1. CHECK NO. 1 COOLING FAN MOTOR Disconnect the No. 1 fan connector. Connect the battery and an ammeter to the No. 1 fan motor connector. Check that the No. 1 fan rotates smoothly, and then check the reading on the ammeter. Standard current CURRENT SPECIFIED CONDITION TABLE Condition Specified Condition w/o Trailer Towing System 6.8 to 9.8 A at 12 V w/ Trailer Towing System 14.6 to 18.7 A at 12 V HINT: Refer to the indication mark for the indication mark location. If the result is not as specified, replace the No. 1 cooling fan motor. Reconnect the No. 1 fan motor connector.
  2. CHECK NO. 2 COOLING FAN MOTOR Disconnect the No. 2 fan connector. Connect the battery and an 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 CURRENT SPECIFIED CONDITION TABLE Condition Specified Condition w/o Trailer Towing System 6.8 to 9.8 A at 12 V w/ Trailer Towing System 14.6 to 18.7 A at 12 V Refer to the indication mark 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 65

Scheme 65: REMOVAL
Scheme 65: REMOVAL

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67

Scheme 68

Scheme 68
Scheme 68
  1. REMOVE RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR HINT: See «REMOVAL»(ref-290672-S21452726162008071700000)
  2. REMOVE FAN ASSEMBLY WITH MOTOR (See «REMOVAL»(ref-290672-S21452726162008071700000) )
  3. REMOVE FAN Remove the 2 nuts and 2 fans.
  4. DISCONNECT COOLING FAN MOTOR CONNECTORS Disconnect the cooling fan motor connectors.
  5. REMOVE NO. 1 COOLING FAN MOTOR Remove the 3 screws and fan motor.
  6. REMOVE NO. 2 COOLING FAN MOTOR Remove the 3 screws and fan motor.

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