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Engine Cooling System ( Hybrid): Overview Toyota Highlander II

Cooling System (Mechanical) 27 illustrations ~3464 words

Scheme 1

Scheme 1: ON-VEHICLE INSPECTION
Scheme 1: ON-VEHICLE INSPECTION
  1. INSPECT FOR COOLANT LEAK (for Engine) 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. Fill the radiator with coolant and attach a radiator cap tester. Pump the tester to 118 kPa (1.2 kgf/cm 2 , 17.1 psi), then check that the pressure does not drop. If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and cylinder head.
  2. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for Engine) The engine coolant level should be between the LOW and FULL lines when the engine is cold. If it is below the LOW line, check for leakage and add Toyota Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line. NOTICE: Do not substitute plain water for engine coolant.
  3. INSPECT ENGINE COOLANT QUALITY (for Engine) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly. Check for excessive deposits of rust or scale around the radiator cap sub-assembly and radiator filler hole. The engine coolant should be free of oil. HINT: If excessively dirty, replace the engine coolant. Install the radiator cap.

DESCRIPTION

The hybrid vehicle control ECU 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 hybrid vehicle control ECU. By basing its control on the operating conditions, the hybrid vehicle control ECU 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 USING TECHSTREAM Connect the Techstream to the DLC3. Turn the power 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 the Techstream. Result RESULT CHART Result Proceed to Both cooling fan motors operate. A Neither of cooling fan motors operates. B Only cooling fan motor does not operate. C Only No. 2 cooling fan motor does not operate. D B: Go to step 2 C: Go to step 6 D: Go to step 17 A: REPLACE HYBRID VEHICLE CONTROL ECU (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#p310-hybrid-vehicle-control-hybrid) )
  2. CHECK HARNESS AND CONNECTOR (NO. 1 FAN MAIN RELAY - BODY GROUND) Turn the power switch on (IG). Remove the NO. 1 FAN MAIN relay from the engine room relay block and junction block. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Switch Condition Specified Condition 1 (NO. 1 FAN MAIN relay) - Body ground Power switch on (IG) 11 to 14 V NG: Go to step 4 OK: Go to next step
  3. CHECK HARNESS AND CONNECTOR (NO. 1 FAN MAIN RELAY - BODY GROUND) Remove the NO. 1 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 Tester Connection Condition Specified Condition 2 (NO. 1 FAN MAIN relay) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE HYBRID VEHICLE CONTROL ECU (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#p310-hybrid-vehicle-control-hybrid) )
  4. INSPECT FUSE (NO. 2 A/C FUSE) Remove the NO. 2 A/C fuse from the instrument panel junction block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition NO. 2 A/C fuse Always Below 1 ohms NG: REPLACE FUSE (NO. 2 A/C FUSE) OK: Go to next step
  5. CHECK HARNESS AND CONNECTOR (NO. 1 FAN MAIN RELAY - NO. 2 A/C FUSE) Remove the NO. 1 FAN MAIN relay from the engine room relay block and junction block. Remove the NO. 2 A/C fuse from the instrument panel junction block. Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 1 FAN MAIN relay) - 2 (NO. 2 A/C fuse) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 1 FAN MAIN relay) and 2 (NO. 2 A/C fuse) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: CHECK SMART KEY SYSTEM
  6. CHECK COOLING FAN SYSTEM Disconnect the hybrid vehicle control ECU connector A43. Turn the power switch on (IG). Check the operation of the cooling fan. OK: The cooling fan motor (main) rotates. NG: Go to step 7 OK: REPLACE HYBRID VEHICLE CONTROL ECU (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#p310-hybrid-vehicle-control-hybrid) )
  7. INSPECT COOLING FAN MOTOR Disconnect the 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 cooling fan motor connector. OK: The cooling fan motor (main) rotates. NG: REPLACE COOLING FAN MOTOR (See «COOLING FAN MOTOR»(ref-305545-S08800898902008112800000) ) OK: Go to next step
  8. CHECK COOLING FAN ECU (POWER SOURCE) Disconnect the cooling fan ECU connector. Turn the power switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Switch Condition Specified Condition A9-1 (+B1) - Body ground Power switch on (IG) 11 to 14 V NG: Go to step 11 OK: Go to next step
  9. 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 Tester Connection Condition Specified Condition A9-3 (E1) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  10. CHECK HARNESS AND CONNECTOR (COOLING FAN ECU - HYBRID VEHICLE CONTROL ECU) Disconnect the A43 connector from the hybrid vehicle control ECU. Disconnect the cooling fan ECU connector. Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A43-14 (RFC1) - A9-2 (SI) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A43-14 (RFC1) and A9-2 (SI) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE COOLING FAN ECU (See «COOLING FAN ECU»(ref-305545-S23585906242008112800000) )
  11. CHECK FUSIBLE LINK BLOCK ASSEMBLY (NO. 1 FAN 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 Tester Connection Condition Specified Condition 1-2 (NO. 1 FAN fuse) Always Below 1 ohms NG: REPLACE FUSE (NO. 1 FAN FUSE) OK: Go to next step
  12. INSPECT COOLING FAN RELAY (NO. 1 FAN MAIN RELAY) Remove the NO. 1 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 Tester Connection Condition Specified Condition 3-5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3-5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms NG: REPLACE COOLING FAN RELAY (NO. 1 FAN MAIN RELAY) OK: Go to next step
  13. CHECK HARNESS AND CONNECTOR (COOLING FAN ECU - NO. 1 FAN MAIN RELAY) Disconnect the cooling fan ECU connector. Remove the NO. 1 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A9-3 (E1) - 2 (NO. 1 FAN MAIN relay) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A9-3 (E1) and 2 (NO. 1 FAN MAIN relay) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  14. CHECK HARNESS AND CONNECTOR (NO. 1 FAN MAIN RELAY - NO. 2 A/C FUSE) Remove the NO. 1 FAN MAIN relay from the engine room relay block and junction block. Remove the NO. 2 A/C fuse from the instrument panel junction block. Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 1 FAN MAIN relay) - 2 (NO. 2 A/C fuse) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 1 FAN MAIN relay) and 2 (NO. 2 A/C fuse) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  15. CHECK HARNESS AND CONNECTOR (COOLING FAN ECU - NO. 1 FAN MAIN RELAY) Disconnect the cooling fan ECU connector. Remove the NO. 1 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A9-1 (+B1) - 5 (NO. 1 FAN MAIN relay) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A9-1 (+B1) and 5 (NO. 1 FAN MAIN relay) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  16. CHECK HARNESS AND CONNECTOR (NO. 1 FAN MAIN RELAY - NO. 1 FAN FUSE) Remove the NO. 1 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3 (NO. 1 FAN MAIN relay) - 2 (NO. 1 FAN fuse) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3 (NO. 1 FAN MAIN relay) and 2 (NO. 1 FAN fuse) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: CHECK SMART KEY SYSTEM
  17. CHECK COOLING FAN SYSTEM Disconnect the hybrid vehicle control ECU connector A43. Turn the power switch on (IG). Check the operation of the cooling fan. OK: The No. 2 cooling fan motor (sub) rotates. NG: Go to step 7 OK: REPLACE HYBRID VEHICLE CONTROL ECU (See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/engine-control-systems/#p310-hybrid-vehicle-control-hybrid) )
  18. 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 motor (sub) rotates. NG: REPLACE NO. 2 COOLING FAN MOTOR OK: Go to next step
  19. CHECK COOLING FAN ECU (POWER SOURCE) Disconnect the cooling fan ECU connector. Turn the power switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Switch Condition Specified Condition A41-1 (+B2) - Body ground Power switch on (IG) 11 to 14 V NG: Go to step 11 OK: Go to next step
  20. CHECK HARNESS AND CONNECTOR (NO. 2 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 Tester Connection Condition Specified Condition A41-3 (E2) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  21. CHECK HARNESS AND CONNECTOR (NO. 2 COOLING FAN ECU - HYBRID VEHICLE CONTROL ECU) Disconnect the A43 connector from the hybrid vehicle control ECU. Disconnect the cooling fan ECU connector. Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A43-10 (RFC2) - A41-2 (SI2) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A43-10 (RFC2) and A41-2 (SI2) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE COOLING FAN ECU (NO. 2) (See «COOLING FAN ECU»(ref-305545-S23585906242008112800000) )
  22. CHECK FUSIBLE LINK BLOCK ASSEMBLY (NO. 2 FAN 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 Tester Connection Condition Specified Condition 1 - 2 (NO. 2 FAN fuse) Always Below 1 ohms NG: REPLACE FUSE (NO. 2 FAN FUSE) OK: Go to next step
  23. INSPECT COOLING FAN RELAY (NO. 2 FAN MAIN RELAY) Remove the NO. 2 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 Tester Connection Condition Specified Condition 3-5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3-5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms NG: REPLACE COOLING FAN RELAY (NO. 2 FAN MAIN RELAY) OK: Go to next step
  24. CHECK HARNESS AND CONNECTOR (NO. 2 COOLING FAN ECU - NO. 2 FAN MAIN RELAY) Disconnect the cooling fan ECU connector. Remove the NO. 2 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A41-3 (E2) - 2 (NO. 2 FAN MAIN relay) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A41-3 (E2) and 2 (NO. 2 FAN MAIN relay) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  25. CHECK HARNESS AND CONNECTOR (NO. 2 FAN MAIN RELAY - NO. 2 A/C FUSE) Remove the NO. 2 FAN MAIN relay from the engine room relay block and junction block. Remove the NO. 2 A/C fuse from the instrument panel junction block. Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 2 FAN MAIN relay) - 2 (NO. 2 A/C fuse) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 (NO. 2 FAN MAIN relay) and 2 (NO. 2 A/C fuse) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  26. CHECK HARNESS AND CONNECTOR (NO. 2 COOLING FAN ECU - NO. 1 FAN MAIN RELAY) Disconnect the cooling fan ECU connector. Remove the NO. 2 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A41-1 (+B1) - 5 (NO. 2 FAN MAIN relay) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A41-1 (+B1) and 5 (NO. 2 FAN MAIN relay) -Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
  27. CHECK HARNESS AND CONNECTOR (NO. 2 FAN MAIN RELAY - NO. 2 FAN FUSE) Remove the NO. 2 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 (Check for open) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3 (NO. 2 FAN MAIN relay) - 2 (NO. 2 FAN fuse) Always Below 1 ohms Standard resistance (Check for short) RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3 (NO. 2 FAN MAIN relay) and 2 (NO. 2 FAN fuse) - Body ground and other terminals Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: CHECK SMART KEY SYSTEM

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Scheme 22: REPLACEMENT
Scheme 22: REPLACEMENT

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  1. DRAIN ENGINE COOLANT (for Engine) Loosen the radiator drain cock plug. CAUTION: To avoid the danger of being burned, do not remove the radiator cap and drain plugs while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. NOTE: Collect the coolant in a container and dispose of it according to the regulations in your area. Loosen the cylinder block drain cock plugs. Remove the radiator cap.
  2. ADD ENGINE COOLANT (for Engine) Tighten the radiator drain cock plug. Tighten the cylinder block drain cock plugs. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf) Loosen the air drain plug. Install a vinyl tube to the vent tube located on the air drain plug. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant. Tighten the air drain plug. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) CAUTION: Do not use an alcohol type coolant or plain water alone. The coolant must be mixed with plain water (preferably demineralized water). Coolant capacity COOLANT CAPACITY REFERENCE Condition Capacity w/ rear heater 12.8 liters (13.5 US qts, 11.2 lmp.qts) w/o rear heater 10.6 liters (11.2 US qts, 9.3 lmp.qts) HINT: Improper coolants may damage the engine cooling system. 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). Use of 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%. 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: Never use water as a substitute for engine coolant. Install the radiator cap securely. Fill the radiator reservoir tank with coolant. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes. HINT: The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose. Stop the engine and wait until the coolant cools down. Remove the radiator cap and check the coolant level inside the radiator. If the coolant level is below the full level, perform the steps from (C) through (K) and repeat the operation until the coolant level stays at the full level. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.
  3. INSPECT FOR COOLANT LEAK (for Engine) (See «ON-VEHICLE INSPECTION»(ref-305545-S29839974482008112800000) )

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Scheme 24: COMPONENTS
Scheme 24: COMPONENTS

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Scheme 26: ON-VEHICLE INSPECTION
Scheme 26: ON-VEHICLE INSPECTION
  1. REMOVE TIMING BELT HINT: See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid)
  2. 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.
  3. INSTALL TIMING BELT HINT: See «INSTALLATION»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid)

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Scheme 27: REMOVAL
Scheme 27: REMOVAL
  1. REMOVE TIMING BELT HINT: See «REMOVAL»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid)
  2. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY (See «DISASSEMBLY»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid) )
  3. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY (See «DISASSEMBLY»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid) )
  4. REMOVE CAMSHAFT TIMING PULLEY (See «DISASSEMBLY»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid) )
  5. REMOVE NO. 3 TIMING BELT COVER (See «DISASSEMBLY»(/toyota/highlander/ii-2007-2010/remont/mechanical/#engine-mechanical-hybrid) )
  6. REMOVE WATER PUMP ASSEMBLY Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket.

See also:
• REMOVAL
• REMOVAL

More articles — Engine Cooling System ( Hybrid)