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Engine Cooling System ( Hybrid): Removal & Installation Toyota Highlander II

Cooling System (Mechanical) 17 illustrations ~1007 words

INSTALLATION

  1. INSTALL WATER PUMP ASSEMBLY Install a new gasket and the water pump with the 3 bolts and 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  2. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY (See «REASSEMBLY»(ref-305543-S26451408082008112800000) )
  3. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY (See «REASSEMBLY»(ref-305543-S26451408082008112800000) )
  4. INSTALL NO. 3 TIMING BELT COVER (See «REASSEMBLY»(ref-305543-S26451408082008112800000) )
  5. INSTALL CAMSHAFT TIMING PULLEY (See «REASSEMBLY»(ref-305543-S26451408082008112800000) )
  6. INSPECT TIMING BELT (See «INSPECTION»(ref-305543-S37319966042008112800000) )
  7. INSTALL TIMING BELT HINT: See «INSTALLATION»(ref-305543-S11495573122008112800000)

Scheme 49

Scheme 49: COMPONENTS
Scheme 49: COMPONENTS

Scheme 50

Scheme 50
Scheme 50

Scheme 51

Scheme 51: REMOVAL
Scheme 51: REMOVAL

Scheme 52

Scheme 52
Scheme 52
  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY HINT: See «REMOVAL»(ref-305549-S25546242362008112800000)
  2. REMOVE WATER INLET PIPE Remove the bolt and the water inlet pipe. Remove the O-ring from the water inlet pipe.
  3. REMOVE WATER INLET Disconnect the wire harness clamp. Remove the 3 nuts and the water inlet.
  4. REMOVE THERMOSTAT Remove the thermostat. Remove the gasket from the thermostat.

Scheme 53

Scheme 53: INSPECTION
Scheme 53: INSPECTION

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55
  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 of the thermostat. Valve opening temperature: 80 to 84°C (176 to 183°F) HINT: If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Valve lift: 10 mm (0.394 in.) or more at 95°C (203°F) HINT: If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat temperature is low (below 77°C (171°F)). HINT: If not closed, replace the thermostat.

Scheme 56

Scheme 56: INSTALLATION
Scheme 56: INSTALLATION
  1. INSTALL THERMOSTAT Install a new gasket to the thermostat. Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing. HINT: The jiggle valve should be set within +/-15° from the prescribed position.
  2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the wire harness clamp.
  3. INSTALL WATER INLET PIPE Install a new O-ring to the water inlet pipe. Apply soapy water to the O-ring. Connect the water inlet pipe to the water inlet. Install the water inlet pipe to the cylinder head with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY HINT: See «INSTALLATION»(ref-305549-S15423948172008112800000)

Scheme 57

Scheme 57: COMPONENTS
Scheme 57: COMPONENTS

Scheme 58

Scheme 58: ON-VEHICLE INSPECTION
Scheme 58: ON-VEHICLE INSPECTION
  1. CHECK COOLING FAN MOTOR Check that the motor turns smoothly when the battery is connected to the fan motor connector. Measure the current while the motor is turning. Standard current: 17.0 to 23.0 A at 20°C (68°F) If the result is not as specified, replace the cooling fan motor.
  2. CHECK NO. 2 COOLING FAN MOTOR Check that the motor turns smoothly when the battery is connected to the fan motor connector. Measure the current while the motor is turning. Standard current: 17.0 to 23.0 A at 20°C (68°F) If the result is not as specified, replace the No. 2 cooling fan motor.

Scheme 59

Scheme 59: REMOVAL
Scheme 59: REMOVAL

Scheme 60

Scheme 60
Scheme 60

Scheme 61

Scheme 61
Scheme 61

Scheme 62

Scheme 62
Scheme 62
  1. REMOVE RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR HINT: See «REMOVAL»(ref-305545-S27770935812008112800000) .
  2. REMOVE FAN ASSEMBLY WITH MOTOR (See «REMOVAL»(ref-305545-S27770935812008112800000) )
  3. REMOVE FAN Remove the 2 nuts and 2 fans.
  4. DISCONNECT COOLING FAN MOTOR CONNECTORS Disconnect the 4 clamps and 2 cooling fan motor connectors.
  5. REMOVE NO. 2 COOLING FAN MOTOR Remove the 3 screws and No. 2 cooling fan motor.
  6. REMOVE COOLING FAN MOTOR Remove the 3 screws and cooling fan motor.
  1. INSTALL COOLING FAN MOTOR Install the cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
  2. INSTALL NO. 2 COOLING FAN MOTOR Install the No. 2 cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
  3. CONNECT COOLING FAN MOTOR CONNECTORS Connect the 4 clamps and 2 cooling fan motor connectors.
  4. INSTALL FAN Install the 2 fans with the 2 nuts. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
  5. INSTALL FAN ASSEMBLY WITH MOTOR (See «INSTALLATION»(ref-305545-S02126103632008112800000) )
  6. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR HINT: See «INSTALLATION»(ref-305545-S02126103632008112800000) .

Scheme 63

Scheme 63: COMPONENTS
Scheme 63: COMPONENTS

Scheme 64

Scheme 64: ON-VEHICLE INSPECTION
Scheme 64: ON-VEHICLE INSPECTION
  1. INSPECT COOLING FAN ECU Put the vehicle in the following conditions: The power switch is off. The coolant temperature is less than 95°C (203°F). The battery voltage is between 11 and 14 V. The A/C switch is off. Clamp the 400 A probe of an ammeter over the M+ wire of each cooling fan motor. Turn the power switch on (IG) and wait for approximately 10 seconds. Check that the fan stops. Start the engine. Check that the fan stops with the engine idling. HINT: Make sure that the radiator engine coolant temperature is less than 95°C (203°F). Turn the A/C switch off. Check that the fan operates when the A/C switch is turned on (MAX COOL and the magnetic clutch is operating). Standard current CURRENT SPECIFIED CONDITION Item Specified Condition Cooling fan motor 4.7 to 6.9 A No. 2 cooling fan motor 4.7 to 6.9 A HINT: The coolant temperature is less than 95°C (203°F). Check that the fan operates when the engine coolant temperature sensor connector is disconnected. Standard current CURRENT SPECIFIED CONDITION Item Specified Condition Cooling fan motor 6.8 to 9.8 A No. 2 cooling fan motor 6.8 to 9.8 A After the engine is warmed up, check that the fan operates as shown in the illustration. HINT: The coolant temperature at which the fan starts operating is approximately 97°C (207°F). This system can also be checked using the Techstream. Select the following menu items: Powertrain / Engine / Data List / Initial Engine Coolant Temp.

Scheme 65

Scheme 65: REMOVAL
Scheme 65: REMOVAL
  1. REMOVE RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR HINT: See «REMOVAL»(ref-305545-S27770935812008112800000) .
  2. REMOVE FAN ASSEMBLY WITH MOTOR (See «REMOVAL»(ref-305545-S27770935812008112800000) )
  3. DISCONNECT COOLING FAN MOTOR CONNECTORS (See «COOLING FAN MOTOR»(ref-305545-S08800898902008112800000) )
  4. REMOVE COOLING FAN ECU Remove the 4 screws and 2 cooling fan ECUs.
  1. INSTALL COOLING FAN ECU Install the 2 ECUs with the 4 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf)
  2. CONNECT COOLING FAN MOTOR CONNECTORS (See «COOLING FAN MOTOR»(ref-305545-S08800898902008112800000) )
  3. INSTALL FAN ASSEMBLY WITH MOTOR (See «INSTALLATION»(ref-305545-S02126103632008112800000) )
  4. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR HINT: See «INSTALLATION»(ref-305545-S02126103632008112800000) .

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