Engine Cooling System: Diagnosis Toyota RAV4 II рестайлинг

INSPECTION

1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the "LOW" and "FULL" lines, when the engine is cold. If 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 up to the "FULL" line. Do not use plain water alone.
2. CHECK ENGINE COOLANT QUALITY Remove the radiator cap from the water outlet. 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 water outlet filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. Reinstall the radiator cap.

ON-VEHICLE INSPECTION

Note. Be sure to do checking when the engine coolant is charged.

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1. Remove the drive belt (See «ON-VEHICLE TESTING»(ref-166399-S26661201402004092000000) ).
2. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.
3. Remove the water pump pulley (see «REMOVAL»(ref-181258-S02070044872005073100000) ).
4. Visually check the inlet hole and drain hole for coolant leakage. If leakage is found, replace the water pump.
5. Reinstall the water pump pulley (see «INSTALLATION»(ref-181258-S04592857342005073100000) ).
6. Reinstall the drive belt (See «ON-VEHICLE TESTING»(ref-166399-S26661201402004092000000) ).

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1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-181258-S32883310702005073100000) )
2. REMOVE DRIVE BELT (See «ON-VEHICLE TESTING»(ref-166399-S26661201402004092000000) )
3. REMOVE WATER PUMP Using SST, remove the 4 bolts and pump pulley. SST 09960-10010 (09962-01000, 09963-00600) Disconnect the crankshaft position sensor wire clamp from the water pump. Disconnect the crankshaft position sensor wire from the clamp on the water pump. Remove the 4 bolts, 2 nuts, wire clamp and water pump. Using a screwdriver, pry between the water pump and cylinder block, and remove the water pump. NOTE: Be careful not to damage the contact surface of the water pump and cylinder block.

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1. INSTALL WATER PUMP 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. 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 the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the water pump (Scheme 7) Seal packing: Part No. 08826-00100 or equivalent Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the water pump and wire clamp with the 4 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Install the crankshaft position sensor wire harness clamp to the water pump. Install the crankshaft position sensor wire to the wire clamp on the water pump. Using SST, install the pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
2. INSTALL DRIVE BELT (See «ON-VEHICLE TESTING»(ref-166399-S26661201402004092000000) )
3. FILL WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR COOLANT LEAKS
5. RECHECK ENGINE COOLANT LEVEL

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INSPECT THERMOSTAT

HINT

The thermostat is numbered with the valve opening temperature.

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1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature. Valve opening temperature: 80 to 84°C (176 to 183.2°F) If the valve opening temperature is not as specified, replace the thermostat.
3. 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.
4. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat.

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1. PLACE THERMOSTAT IN CYLINDER BLOCK Install a new gasket to the thermostat. Install the thermostat with the jiggle valve upward. HINT: The jiggle valve may be set within 10° of either side of the prescribed position.
2. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
3. INSTALL GENERATOR (See «GENERATOR»(ref-166399-S39294526262004092000000) )
4. INSTALL DRIVE BELT (See «ON-VEHICLE TESTING»(ref-166399-S26661201402004092000000) )
5. FILL WITH ENGINE COOLANT (See «REPLACEMENT»(ref-181258-S32883310702005073100000) )
6. START ENGINE AND CHECK FOR LEAKS
7. RECHECK ENGINE COOLANT LEVEL

INSPECT FINS FOR BLOCKAGE

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

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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 PRESSURE AND DISTANCE SPECIFICATIONS Injection Pressure Injection Distance 2,942 to 4,903 kPa (30 to 80 kgf.cm 2 , 427 to 711 psi) 300 mm (11.811 in.) 4,903 to 7,845 kPa (50 to 80 kgf.cm 2 , 711 to 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 second 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 to 123 kPa (0.95 to 1.25 kgf/cm 2 ,13.5 to 17.8 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm 2 ,11.4 psi) HINT: 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 118 kPa (1.2 kgf/cm 2 ,17.1 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 RADIATOR GRILLE Remove the 4 screws, 2 clips and radiator grille.
3. REMOVE FRONT END PANEL Remove the 4 screws and front end panel.
4. DISCONNECT HOOD LOCK Remove the 3 bolts, and disconnect the hood lock. Disconnect the wire from the clamp.
5. DISCONNECT UPPER RADIATOR HOSE
6. REMOVE UPPER RADIATOR SUPPORT Remove the 5 bolts and radiator support.
7. REMOVE LH ENGINE UNDER COVER
8. REMOVE RADIATOR RESERVOIR
9. REMOVE NO. 1 AND NO. 2 COOLING FANS (See «ELECTRIC COOLING FANS»(ref-164295) )
10. A/T: DISCONNECT OIL 2 HOSES Disconnect the 2 oil cooler hoses from the radiator.
11. DISCONNECT LOWER RADIATOR HOSE
12. REMOVE RADIATOR
13. REMOVE UPPER AND LOWER RADIATOR SUPPORTS FROM RADIATOR

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1. REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring.
2. ASSEMBLE SST SST 09230-01010 Install the claw to the overhaul handle, inserting it in the hole in part "A" (Scheme 25) While gripping the handle, adjust the stopper bolt so that dimension "B" is (Scheme 25) Dimension: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
3. UNCAULK LOCK PLATES Using SST to release the caulking, grip the handle until stopped by the stopper bolt. SST 09230-01010
4. REMOVE TANKS AND O-RINGS Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer, and remove the tank. Remove the O-ring.
5. A/T: REMOVE OIL COOLER PIPES FROM LOWER TANK Remove the 2 cooler pipes Loosen the 2 nuts, and remove the 2 pipes. Remove the 2 nuts. Remove the 2 O-rings from the oil cooler.

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1. A/T: INSTALL OIL COOLER PIPES TO LOWER TANK Install 2 new O-rings to the oil cooler. Install the 2 nuts. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Install the LH cooler pipe in the direction indicated in (Scheme 29). Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf) Install the RH cooler pipe. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
2. INSPECT LOCK PLATE FOR DAMAGE HINT: 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 or dented. Repair or replace if necessary. NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
3. INSTALL NEW O-RINGS AND TANKS After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: 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 the lock plate and the tank.
4. ASSEMBLE SST SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" (Scheme 33) While gripping the handle, adjust the stopper bolt so that dimension "B" is (Scheme 33) Dimension: 8.4 mm (0.331 in)
5. CAULK LOCK PLATE Lightly press SST against the lock plate in the order (Scheme 34) After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs. The points (Scheme 36)and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. Check the lock plate height (H) after completing the caulking. Plate height (H): 8.45 to 8.85 mm (0.3327 to 0.3484 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
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/cm 2, 26 psi) Submerge the radiator in water. Inspect for leaks. HINT: On radiators with resin tanks, 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 air bubbles disappear.

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1. INSTALL UPPER AND LOWER RADIATOR SUPPORTS TO RADIATOR
2. INSTALL RADIATOR
3. CONNECT LOWER RADIATOR HOSE
4. A/T: CONNECT 2 HOSES Connect the 2 oil cooler hoses to the radiator.
5. INSTALL NO. 1 AND NO. 2 COOLING FANS (See «ELECTRIC COOLING FANS»(ref-164295) )
6. INSTALL RADIATOR RESERVOIR
7. INSTALL RH ENGINE UNDER COVER
8. INSTALL UPPER RADIATOR SUPPORT Install the radiator upper support with the 5 bolts.
9. CONNECT UPPER RADIATOR HOSE
10. CONNECT HOOD LOCK Install the hood lock with the 3 bolts. Install the wire from the clamps.
11. INSTALL FRONT END PANEL Install the front end panel with the 4 screws.
12. INSTALL RADIATOR GRILLE Install the radiator grille with the 4 screws and 2 clips.
13. FILL WITH ENGINE COOLANT
14. START ENGINE AND CHECK FOR COOLANT LEAKS