COOLING SYSTEM

1NZ-FE COOLING – COOLING SYSTEM
CO–1
COOLING SYSTEM
ON-VEHICLE INSPECTION
CAUTION:
Be sure that the ignition is off if you work near the
electric cooling fans or radiator grille. With the ignition
on the electric cooling fans may automatically start to
run if the engine coolant temperature is high and/or the
air conditioning is on.
1.
CHECK COOLING SYSTEM FOR LEAKAGE
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.
(a) Fill the radiator assembly with engine coolant, then
attach a radiator cap tester.
(b) Pump the tester to 137 kPa (1.4 kgf/cm2, 19.9 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 head.
A106594
2.
INSPECT RESERVOIR TANK ENGINE COOLANT
LEVEL
(a) The engine coolant should be between the LOW
and FULL lines when the engine is cold.
HINT:
If it is below the LOW line, check for leakage and
add Toyota Super Long Life Coolant or similar high
quality ethylene glycol based non-silicate, nonamine, non-nitrite, and non-borate coolant with longlife hybrid organic acid technology up to the FULL
line.
3.
INSPECT ENGINE COOLANT QUALITY
(a) Remove the radiator cap sub-assembly.
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.
(b) 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.
If excessively dirty, replace the engine coolant.
(c) Reinstall the radiator cap sub-assembly.
CO
CO–2
1NZ-FE COOLING – COOLING SYSTEM
4.
A073603E02
INSPECT FINS FOR BLOCKAGE
(a) If the fins are clogged, wash them with water or a
steam cleaner and dry them with compressed air.
NOTICE:
• To avoid damaging the fins, the injection
direction should be at right angles to the core
surface.
• If the steam cleaner is too close to the core,
there is a possibility of damaging the fins, so
keep to the following injection distances.
Injection Pressure
kPa (kgf*cm2, psi)
Injection Distance
mm (in.)
2.942 to 4.903
(30 to 50, 427 to 711)
300 (11.811)
4.903 to 7.845
(50 to 80, 711 to 1.138)
500 (19.685)
• If the fins are bent, straighten them with a
screwdriver or pliers.
• Do not expose electronic components to
water.
CO
CO–3
1NZ-FE COOLING – COOLING FAN SYSTEM
COOLING FAN SYSTEM
1NZ-FE COOLING
ENGINE
PARTS LOCATION
INTEGRATION RELAY
(COOLING FAN RELAY)
COOLING FAN RELAY NO. 2
ENGINE ROOM R/B, J/B
- COOLING FAN RELAY NO. 2
- INTEGRATION RELAY
(COOLING FAN RELAY)
ECM
- RDI FUSE
- AM2 FUSE
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
RADIATOR FAN WITH MOTOR
COOLING FAN RESISTOR
A108452E02
CO
CO–4
1NZ-FE COOLING – COOLING FAN SYSTEM
MAIN BODY ECU
- ECU-IG FUSE
- AM1 FUSE
- IG 1 Relay
CO
A117368E03
CO–5
1NZ-FE COOLING – COOLING FAN SYSTEM
SYSTEM DIAGRAM
Engine Coolant Temperature (ECT) Sensor
ECM
THW
Integration
(Cooling Fan)
ETHW
FAN
Cooling Fan No. 2
Radiator Fan with Motor
CO
FAN2
RAD
ECU-IG
Cooling Fan Resistor
AM1
IG 1
Ignition Switch
ALT
Battery
A117350E01
CO–6
1NZ-FE COOLING – COOLING FAN SYSTEM
ON-VEHICLE INSPECTION
CAUTION:
Be sure that the ignition is off if you work near the
electric cooling fans or radiator grille. With the ignition
on the electric cooling fans may automatically start to
run if the engine coolant temperature is high and/or the
air conditioning is on.
1.
INSPECT COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 83°C (181°F))
(a) Turn the ignition switch on (IG) and air conditioning
switch off.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine
coolant temperature sensor, and check whether
there is disconnection or an open circuit between
them.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) 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 cooing fan relay and the engine coolant
temperature sensor.
(e) Reconnect the engine coolant temperature sensor
connector.
2.
INSPECT COOLING FAN OPERATION AT HIGH
TEMPERATURES (Above 93°C (199°F))
(a) Start the engine and air conditioning switch off, and
raise the engine coolant temperature to above 93°C
(199°F).
HINT:
Engine coolant temperature is detected by the
engine coolant temperature sensor on the water
outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature
sensor.
3.
INSPECT COOLING FAN MOTOR
(a) Disconnect the cooling fan motor connector.
(b) Connect the cooling fan connector to the battery
and check that the fan motor moves smoothly.
CO
1NZ-FE COOLING – COOLING FAN SYSTEM
CO–7
(c) Using an ammeter, measure the current between
the terminals.
Standard Current:
w/ A/C 11.8 to 14.8 A (at 12 V)
w/o A/C 7.9 to 10.9 A (at 12 V)
(d) Connect the cooling fan motor connector.
A108453
CO
CO–8
1NZ-FE COOLING – COOLANT
COOLANT
REPLACEMENT
CAUTION:
Be sure that the ignition is off if you work near the
electric cooling fans or radiator grille. With the ignition
on the electric cooling fans may automatically start to
run if the engine coolant temperature is high and/or the
air conditioning is on.
1.
DRAIN ENGINE COOLANT
NOTICE:
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.
(a) Loosen the radiator drain cock plug.
(b) Remove the radiator cap sub-assembly.
(c) Loosen the cylinder block drain cock plug, then
drain the coolant.
CO
Cylinder Block Drain Cock
Radiator Cap Sub-Assembly
Radiator Drain Cock Plug
A106596E01
2.
ADD ENGINE COOLANT
(a) Tighten all the plugs.
1NZ-FE COOLING – COOLANT
CO–9
(b) Pour engine coolant into the radiator assembly until
it overflows.
Capacity:
M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)
A/T 4.7 liters (5.0 USqts, 4.4 lmp. qts)
NOTICE:
Do not substitute water for engine coolant.
HINT:
• Use of improper engine coolant may damage the
engine coolant system.
• Use only Toyota Super Long Life Coolant or
similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and non-borate
engine 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).
(c) Check the engine coolant level inside the radiator
assembly by squeezing the inlet and outlet radiator
hoses several times by hand. If the engine coolant
level goes down, add engine coolant.
(d) Install the radiator cap sub-assembly securely.
(e) Slowly pour engine coolant into the radiator
reservoir until it reaches the FULL line.
(f) Warm up the engine until the cooling fan operates.
(1) Set the air conditioning as follows while
warming up the engine.
Item
Set control as follows
Manual air conditioning system
Automatic air conditioning system
Fan speed - Any setting except "OFF"
Temperature - Toward WARM
Air conditioning switch "OFF"
Fan speed - Any setting except "OFF"
Temperature - To the highest temperature
Air conditioning switch "OFF"
"AUTO" switch "OFF"
(2) Maintain the engine speed at 2,000 to 2,500
rpm and warm up the engine until the cooling
fan operates.
(g) Stop the engine and wait until the coolant cools
down.
(h) If the engine coolant level is below the full level,
perform steps (b) through (g) again and repeat the
operation until the engine coolant level stays at the
full level.
(i) Recheck the engine coolant level inside the radiator
reservoir tank assembly. If it is below the full level,
add engine coolant.
3.
CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
CO
CO–10
1NZ-FE COOLING – WATER PUMP
WATER PUMP
1NZ-FE COOLING
ENGINE
COMPONENTS
CO
5.0 (51, 44 in.*lbf)
ENGINE UNDER COVER RH
N*m (kgf*cm, ft.*lbf) : Specified torque
A115143E01
CO–11
1NZ-FE COOLING – WATER PUMP
CO
19 (189, 14)
54 (551, 40)
FAN AND GENERATOR V BELT
N*m (kgf*cm, ft.*lbf) : Specified torque
A116199E01
CO–12
1NZ-FE COOLING – WATER PUMP
for Hatchback:
11 (112, 8.1)
FAN BELT ADJUSTING BAR
19 (189, 14)
54 (551, 40)
x2
GENERATOR
ASSEMBLY
45 (459, 33)
52 (530, 38)
x3
9.8 (100, 7.2)
CO
ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH
52 (530, 38)
N*m (kgf*cm, ft.*lbf) : Specified torque
A116193E06
CO–13
1NZ-FE COOLING – WATER PUMP
for Sedan:
11 (112, 8.1)
FAN BELT ADJUSTING BAR
19 (189, 14)
54 (551, 40)
52 (530, 38)
x2
GENERATOR
ASSEMBLY
52 (530, 38)
x3
9.8 (100, 7.2)
CO
ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH
52 (530, 38)
N*m (kgf*cm, ft*lbf) : Specified torque
A133594E01
CO–14
1NZ-FE COOLING – WATER PUMP
CO
GASKET
11 (112, 8.1)
x2
x3
x3
15 (153, 11)
WATER PUMP ASSEMBLY
11 (112, 8.1)
WATER PUMP PULLEY
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A116194E01
1NZ-FE COOLING – WATER PUMP
CO–15
REMOVAL
1.
DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2.
REMOVE ENGINE COOLANT (See page CO-8)
3.
REMOVE ENGINE UNDER COVER RH
4.
REMOVE FAN AND GENERATOR V BELT (See page
EM-7)
5.
REMOVE GENERATOR ASSEMBLY (See page CH-10)
6.
REMOVE ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (See page LU-17)
7.
REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 3 bolts and remove the water pump
pulley.
CO
SST
A116191E01
8.
A116192
REMOVE WATER PUMP ASSEMBLY
(a) Remove the 3 bolts and 2 nuts and remove the
water pump assembly and gasket.
CO–16
1NZ-FE COOLING – WATER PUMP
INSPECTION
1.
INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole for coolant leakage.
(b) Turn the pulley and check that the water pump
bearing moves smoothly and does not make any
noise.
If necessary, replace the water pump assembly.
Turn
A037047E02
INSTALLATION
1.
INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump assembly through a new
gasket with the 3 bolts and 2 nuts.
Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf)
2.
INSTALL WATER PUMP PULLEY
(a) Provisionally install the water pump pulley with the 3
bolts.
CO
A116192
(b) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(c) Tighten the 3 bolts to the specified torque.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
SST
A116191E01
3.
INSTALL ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (for Hatchback) (See page LU-26)
4.
INSTALL ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (for Sedan) (See page LU-26)
5.
INSTALL GENERATOR ASSEMBLY (See page CH-17)
6.
INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
7.
ADJUST FAN AND GENERATOR V BELT (See page
EM-7)
8.
INSPECT FAN AND GENERATOR V BELT (See page
EM-8)
9.
CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
10. ADD ENGINE COOLANT (See page CO-8)
11. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
12. INSTALL ENGINE UNDER COVER RH
CO–17
1NZ-FE COOLING – THERMOSTAT
THERMOSTAT
1NZ-FE COOLING
ENGINE
COMPONENTS
CO
THERMOSTAT
GASKET
WATER INLET
9.0 (92, 80 in.*lbf)
9.0 (92, 80 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A116190E01
CO–18
1NZ-FE COOLING – THERMOSTAT
REMOVAL
1.
DRAIN ENGINE COOLANT (See page CO-8)
2.
REMOVE WATER INLET
(a) Remove the 2 nuts and separate the water inlet with
radiator hose from the cylinder block.
3.
REMOVE THERMOSTAT
(a) Remove the thermostat from the cylinder block.
(b) Remove the gasket from the thermostat.
A116186
CO
A116187
INSPECTION
1.
INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the
thermostat.
A116189
(a) Immerse the thermostat in water and gradually heat
the water.
(b) Check the valve opening temperature of the
thermostat.
Valve opening temperature:
80 to 84°C (176 to 183°F)
If the valve opening temperature is not as specified,
replace the thermostat.
P000436E01
1NZ-FE COOLING – THERMOSTAT
Valve Lift
CO–19
(c) Check the valve lift.
Valve lift:
8.5 mm (0.335 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the
thermostat.
(d) Check that the valve is fully closed when the
thermostat is at low temperatures (below 77°C
(171°F))
If not fully closed, replace the thermostat.
P024125E01
CO
CO–20
1NZ-FE COOLING – THERMOSTAT
INSTALLATION
1.
10q
INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve facing
upward.
HINT:
The jiggle valve may be set within 10° on either
side, as shown in the illustration.
10q
A116188E01
CO
A116186
2.
INSTALL WATER INLET
(a) Install the water inlet with radiator hose with the 2
nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3.
ADD ENGINE COOLANT (See page CO-8)
4.
CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
CO–20
1NZ-FE COOLING – COOLING FAN RELAY
COOLING FAN RELAY
ON-VEHICLE INSPECTION
1.
A030519
INSPECT COOLING FAN RELAY NO. 2
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
Tester Connection
Specified Condition
3-4
Below 1 Ω
3-4
10 kΩ or higher (When battery
voltage applied to terminals 1 and 2)
3-5
10 kΩ or higher
3-5
Below 1 Ω (when battery voltage
applied to terminals 1 and 2)
If the result is not as specified, replace the
relay.
CO
1NZ-FE COOLING – INTEGRATION RELAY
CO–21
INTEGRATION RELAY
1NZ-FE COOLING
ENGINE
COMPONENTS
RELAY BLOCK COVER NO. 1
CO
INTEGRATION RELAY
A115401E01
CO–22
1NZ-FE COOLING – INTEGRATION RELAY
REMOVAL
1.
DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2.
REMOVE RELAY BLOCK COVER NO. 1
3.
REMOVE INTEGRATION RELAY
(a) Using a screwdriver with its tip wrapped in
protective tape, disengage the 2 claws and
disconnect the integration relay.
(b) Disconnect the 3 connectors.
A115400
CO
INSPECTION
1.
C
B
A
A125205E01
INSPECT INTEGRATION RELAY
(a) Inspect the cooling fan relay.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
Tester connection
Specified condition
B5 - B8
10 kΩ or higher
B5 - B8
Below 1 Ω
(Battery voltage applied between
terminals B6 and B7)
NOTICE:
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.
1NZ-FE COOLING – INTEGRATION RELAY
CO–23
INSTALLATION
1.
INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Attach the integration relay to the engine room relay
block.
2.
INSTALL RELAY BLOCK COVER NO. 1
3.
CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 4.8 in.*lbf)
CO
1NZ-FE COOLING – COOLING FAN RESISTOR
CO–23
COOLING FAN RESISTOR
1NZ-FE COOLING
ENGINE
COMPONENTS
CO
COOLING FAN RESISTOR
5.1 (52, 45 in.*lbf)
FRONT FENDER LINER LH
N*m (kgf*cm, ft.*lbf) : Specified torque
A108462E10
CO–24
1NZ-FE COOLING – COOLING FAN RESISTOR
REMOVAL
1.
DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2.
REMOVE FRONT WHEEL LH
3.
REMOVE FRONT FENDER LINER LH (See page BC95)
4.
REMOVE COOLING FAN RESISTOR
(a) Disconnect the connector from the cooling fan
resistor.
(b) Remove the 2 bolts and the cooling fan resistor.
A108461
INSPECTION
1.
CO
2 1
INSPECT COOLING FAN RESISTOR
(a) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance:
1.17 to 1.43 Ω at 20°C (68°F)
A104872E01
INSTALLATION
A108461
1.
INSTALL COOLING FAN RESISTOR
(a) Install the cooling fan resistor with the 2 bolts.
Torque: 5.1 N*m (52 kgf*cm, 45 in.*lbf)
(b) Connect the cooling fan resistor connector.
2.
INSTALL FRONT FENDER LINER LH (See page BC96)
3.
INSTALL FRONT WHEEL LH
4.
CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
1NZ-FE COOLING – RADIATOR
CO–25
RADIATOR
1NZ-FE COOLING
ENGINE
COMPONENTS
for Hatchback:
CO
x5
FRONT BUMPER COVER
x2
x3
x3
x3
x2
A117338E07
CO–26
1NZ-FE COOLING – RADIATOR
for Sedan:
CO
CLIP
x6
FRONT BUMPER COVER
x2
x3
x3
x3
x2
A128449E06
CO–27
1NZ-FE COOLING – RADIATOR
FUEL VAPOR FEED
HOSE NO. 1
VENTILATION HOSE
AIR CLEANER HOSE NO. 1
FUEL VAPOR FEED HOSE
5.5 (56, 49 in.*lbf)
x2
AIR CLEANER CAP
RADIATOR SUPPORT
SUB-ASSEMBLY UPPER
AIR CLEANER
ELEMENT
5.5 (56, 49 in.*lbf)
x2
7.8 (80, 69 in.*lbf)
CO
RADIATOR SUPPORT
ABSORBER UPPER
AIR CLEANER
ASSEMBLY
AIR CLEANER CACE
AIR CLEANER INLET NO. 1
w/ No. 1 Cooler Cover:
NO. 1 COOLER
COVER
for Sedan:
RADIATOR HOSE NO. 3
x2
HOOD LOCK ASSEMBLY
RADIATOR SUPPORT
SUB-ASSEMBLY UPPER
x3
x2
7.5 (76, 66 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
5.5 (56, 49 in.*lbf)
5.5 (56, 49 in.*lbf)
A136452E02
CO–28
1NZ-FE COOLING – RADIATOR
for Automatic Transaxle:
RADIATOR SUPPORT CUSHION
OIL COOLER OUTLET HOSE
RADIATOR HOSE NO. 2
FAN SHROUD
CO
RADIATOR
DRAIN COCK
OIL COOLER
INLET HOSE
RADIATOR ASSEMBLY
RADIATOR RESERVE TANK HOSE GROMMET
A117357E05
CO–29
1NZ-FE COOLING – RADIATOR
for Manual Transaxle:
RADIATOR SUPPORT CUSHION
RADIATOR HOSE NO. 2
FAN SHROUD
CO
RADIATOR
ASSEMBLY
RADIATOR DRAIN COCK
RADIATOR RESERVE TANK HOSE GROMMET
A117358E04
CO–30
1NZ-FE COOLING – RADIATOR
ON-VEHICLE INSPECTION
1.
1
2
4
3
A107446E01
Radiator Cap Tester
CO
30° or more
Radiator Cap
A104601E03
CHECK RADIATOR CAP SUB-ASSEMBLY
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on
rubber packings 1, 2 or 3, clean the part(s) with
water and finger scouring.
(2) Check that rubber packings 1, 2 and 3 are not
deformed, cracked or swollen.
(3) Check that rubber packings 3 and 4 are not
stuck together.
(4) Apply engine coolant to rubber packings 2 and
3 before using a radiator cap tester.
(5) When using the cap tester, tilt it to 30° or more
above the horizontal.
(6) Pump the cap tester several times, and check
the maximum pressure *1.
Pumping speed:
1 pumps every second
*1: Even if the cap cannot maintain the
maximum pressure, it is not a defect.
Judgment Criteria
Item
Specified Condition
Standard valve
(for brand-new cap)
93.3 to 122.7 kPa (0.95 to 1.25 kgf/
Minimum standard valve
(after using cap)
cm2, 13.5 to 17.8 psi)
78.5 kPa (0.8 kgf/cm2, 11.4 psi)
If the maximum pressure is less than the
specified pressure for the minimum standard
valve, replace the radiator cap sub-assembly.
1NZ-FE COOLING – RADIATOR
CO–31
REMOVAL
CAUTION:
Be sure that the ignition is off if you work near the
electric cooling fans or radiator grille. With the ignition
on the electric cooling fans may automatically start to
run if the engine coolant temperature is high and/or the
air conditioning is on.
1.
DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2.
DRAIN ENGINE COOLANT (See page CO-8)
3.
REMOVE FRONT BUMPER COVER (for Hatchback)
(See page ET-24)
4.
REMOVE FRONT BUMPER COVER (for Sedan) (See
page ET-6)
5.
REMOVE AIR CLEANER ASSEMBLY
(a) Separate the intake air flow meter connector and
the wire harness clamp.
(b) Separate the fuel vapor feed hose and fuel vapor
feed hose No. 1 from the vacuum switching valve
assembly.
(c) Separate the vacuum switching valve connector and
the wire harness clamp.
(d) Separate the ventilation hose from the air cleaner
hose.
(e) Release the air cleaner cap with air cleaner hose
No. 1.
(f) Loosen the air cleaner hose clamp on the throttle
body side and remove the air cleaner cap and the
air cleaner hose.
(g) Remove the air cleaner element.
A117355
(h) Separate the wire harness clamp from the air
cleaner case.
(i) Remove the 2 bolts and remove the air cleaner case
with air cleaner inlet No. 1.
A104895
6.
A104886E01
REMOVE RADIATOR SUPPORT ABSORBER UPPER
(for Hatchback)
(a) Disengage the 6 claws and remove the radiator
support absorber upper.
CO
CO–32
1NZ-FE COOLING – RADIATOR
7.
REMOVE NO. 1 COOLER COVER (w/ No. 1 Cooler
Cover)
(a) Remove the 2 clips and No. 1 cooler cover.
8.
REMOVE HOOD LOCK ASSEMBLY (w/ Theft
Deterrent System)
(a) Separate the hood lock control cable assembly from
the 2 clamps.
A109229
CO
A108455
(b) Separate the engine hood courtesy switch
connector.
(c) Remove the 3 bolts and remove the hood lock
assembly.
A117345
9.
A108455
REMOVE HOOD LOCK ASSEMBLY (w/o Theft
Deterrent System)
(a) Separate the hood lock control cable assembly from
the 2 clamps.
1NZ-FE COOLING – RADIATOR
CO–33
(b) Remove the 3 bolts and remove the hood lock
assembly.
A108456
10. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY
UPPER
(a) Separate the horn assembly connector.
(b) Remove the 4 bolts and remove the radiator support
sub-assembly upper.
for Hatchback:
for Sedan:
CO
A128451E01
11. DISCONNECT RADIATOR RESERVOIR TANK HOSE
(a) Disconnect the radiator reservoir tank hose from the
water filler.
A117356
12. REMOVE RADIATOR HOSE NO. 3
(a) Loosen the 2 clips and remove radiator hose No. 3.
A117310E01
CO–34
1NZ-FE COOLING – RADIATOR
13. DISCONNECT RADIATOR HOSE NO. 2
(a) Loosen the clip and disconnect radiator hose No. 2.
A104893
14. DISCONNECT OIL COOLER OUTLET HOSE (for
Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler outlet
hose.
A117306
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15. DISCONNECT OIL COOLER INLET HOSE (for
Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler inlet
hose.
A117307
16. REMOVE RADIATOR ASSEMBLY (w/ Air
Conditioning System)
(a) Separate the cooling fan motor connector and wire
harness clamps.
A104896
1NZ-FE COOLING – RADIATOR
CO–35
(b) Disengage the 2 claws and remove the radiator
assembly from the vehicle.
NOTICE:
Do not apply excessive force to the cooler
condenser assembly or piping when removing
the radiator assembly.
A104897
17. REMOVE RADIATOR ASSEMBLY (w/o Air
Conditioning System)
(a) Separate the cooling fan motor connector and wire
harness clamps.
(b) Remove the radiator assembly from the vehicle.
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A104896
18. REMOVE RADIATOR HOSE NO. 2
(a) Loosen the clip and remove radiator hose No. 2.
A104898
19. REMOVE OIL COOLER OUTLET HOSE (for
Automatic Transaxle)
(a) Loosen the clip and remove the cooler outlet hose.
A106602
CO–36
1NZ-FE COOLING – RADIATOR
20. REMOVE OIL COOLER INLET HOSE (for Automatic
Transaxle)
(a) Loosen the clip and remove the cooler inlet hose.
A106603
21. REMOVE FAN SHROUD
(a) Disengage the 2 claws and remove the fan shroud.
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A104899
22. REMOVE RADIATOR SUPPORT CUSHION
(a) Remove the 2 radiator support cushions from the
radiator assembly.
A104900
23. REMOVE RADIATOR RESERVE TANK HOSE
GROMMET
(a) Remove the 2 radiator reserve tank hose grommets
from the radiator assembly.
A106604
1NZ-FE COOLING – RADIATOR
CO–37
24. REMOVE RADIATOR DRAIN COCK
(a) Remove the radiator drain cock from the radiator
assembly.
A106605
INSTALLATION
1.
INSTALL RADIATOR DRAIN COCK
(a) Install the radiator drain cock onto the radiator
assembly.
2.
INSTALL RADIATOR RESERVE TANK HOSE
GROMMET
(a) Install the 2 radiator reserve tank hose grommets
onto the radiator assembly.
3.
INSTALL RADIATOR SUPPORT CUSHION
(a) Install the 2 radiator support cushions onto the
radiator assembly.
A106605
A106604
A104900
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CO–38
1NZ-FE COOLING – RADIATOR
4.
INSTALL FAN SHROUD
(a) Engage the 2 claws and install the fan shroud.
5.
INSTALL OIL COOLER INLET HOSE (for Automatic
Transaxle)
(a) Install the oil cooler inlet hose with the clip.
6.
INSTALL OIL COOLER OUTLET HOSE (for Automatic
Transaxle)
(a) Install the oil cooler outlet hose with the clip.
7.
INSTALL RADIATOR HOSE NO. 2
(a) Install radiator hose No. 2 with the clip.
A104899
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A106603
A106602
A104898
1NZ-FE COOLING – RADIATOR
8.
CO–39
INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning
System)
(a) Engage the 2 claws and install the radiator
assembly into the vehicle.
NOTICE:
Do not apply excessive force to the cooler
condenser assembly or piping when installing
the radiator assembly.
A104897
(b) Connect the cooling fan motor connector and wire
harness clamps.
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A104896
9.
INSTALL RADIATOR ASSEMBLY (w/o Air
Conditioning System)
(a) Install the radiator assembly into the vehicle.
(b) Connect the cooling fan motor connector and wire
harness clamps.
A104896
10. CONNECT OIL COOLER INLET HOSE (for Automatic
Transaxle)
(a) Connect the oil cooler inlet hose with the clip.
A117307
CO–40
1NZ-FE COOLING – RADIATOR
11. CONNECT OIL COOLER OUTLET HOSE (for
Automatic Transaxle)
(a) Connect the oil cooler outlet hose with the clip.
A117306
12. CONNECT RADIATOR HOSE NO. 2
(a) Connect radiator hose No. 2 with the clip.
A104893
CO
13. INSTALL RADIATOR HOSE NO. 3
(a) Install radiator hose No. 3 with the 2 clips.
A117310E01
14. CONNECT RADIATOR RESERVOIR TANK HOSE
(a) Connect the radiator reservoir tank hose to the
water filler.
A117356
1NZ-FE COOLING – RADIATOR
CO–41
15. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY
UPPER
(a) Install the radiator support sub-assembly upper with
the 4 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
(b) Connect the horn assembly connector.
for Hatchback:
for Sedan:
A128451E01
16. INSTALL HOOD LOCK ASSEMBLY (w/ Theft
Deterrent System)
(a) Temporarily install the hood lock assembly with the
3 bolts.
(b) Connect the engine hood courtesy switch
connector.
A117345
(c) Connect the hood lock control cable assembly to the
2 clamps.
A108455
17. INSTALL HOOD LOCK ASSEMBLY (w/o Theft
Deterrent System)
(a) Temporarily install the hood lock assembly with the
3 bolts.
A108456
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CO–42
1NZ-FE COOLING – RADIATOR
(b) Connect the hood lock control cable assembly to the
2 clamps.
A108455
18. INSTALL NO. 1 COOLER COVER (w/ No. 1 Cooler
Cover)
(a) Insert the 2 pins of No. 1 cooler cover into the
radiator support LWR.
(b) Install No. 1 cooler cover with the 2 clips.
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A109229
19. INSTALL RADIATOR SUPPORT ABSORBER UPPER
(for Hatchback)
(a) Engage the 6 claws and install the radiator support
absorber upper.
A104886E01
20. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with air cleaner inlet No.
1 with the 2 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
(b) Connect the wire harness to the air cleaner case.
(c) Install the air cleaner element.
A104895
1NZ-FE COOLING – RADIATOR
CO–43
(d) Install and lock the air cleaner cap and air cleaner
hose and then tighten the air cleaner hose clamp.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
(e) Connect the ventilation hose to the air cleaner hose.
(f) Connect the vacuum switching valve connector and
wire harness clamp.
(g) Connect the fuel vapor feed hose and fuel vapor
feed hose No. 1 to the vacuum switching valve
assembly.
(h) Connect the intake air flow meter connector and
wire harness clamp.
21. INSTALL FRONT BUMPER COVER (for Hatchback)
(See page ET-33)
A117355
22. INSTALL FRONT BUMPER COVER (for Sedan) (See
page ET-16)
23. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
24. ADD ENGINE COOLANT (See page CO-8)
25. ADJUST HOOD LOCK ASSEMBLY
(a) Loosen the 3 bolts.
(b) Adjust the hood lock position so that the striker can
enter it smoothly.
(c) Tighten the 3 bolts after the adjustment.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
26. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
B106964
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