1NZ-FXE COOLING – COOLING SYSTEM CO–1 COOLING SYSTEM 1NZ-FXE COOLING ENGINE PARTS LOCATION RADIATOR CAP CO THERMOSTAT A124645E01 CO–2 1NZ-FXE COOLING – COOLING SYSTEM ON-VEHICLE INSPECTION 1. CHECK COOLING SYSTEM FOR LEAKS 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. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using the radiator cap tester, increase the pressure inside the radiator to 177 kPa (1.8 kgf/cm2, 25.6 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 cylinder block and head. A088171E01 2. CHECK ENGINE COOLANT LEVEL IN RESERVOIR (a) The engine coolant 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 (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology up to the full line. NOTICE: Never use water as a substitute for engine coolant. 3. CHECK ENGINE COOLANT QUALITY (a) 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. (b) Check if there are excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, replace the coolant. (c) Install the radiator cap. CO CO–3 1NZ-FXE COOLING – COOLING FAN SYSTEM COOLING FAN SYSTEM 1NZ-FXE COOLING ENGINE PARTS LOCATION ENGINE COOLANT TEMPERATURE SENSOR CO COOLING FAN MOTOR ENGINE ROOM RELAY BLOCK, JUNCTION BLOCK - RDI H-FUSE - NO. 2 FAN RELAY (Marking: FAN NO. 2) - CDS FAN FUSE - NO. 3 FAN RELAY (Marking: FAN NO. 3) - INTEGRATION RELAY (UNIT C: NO. 1 (FAN NO. 1) RELAY) ECM A/C AMPLIFIER A124646E01 CO–4 1NZ-FXE COOLING – COOLING FAN SYSTEM SYSTEM DIAGRAM from Battery from IG RDI CO from Battery ECU-IG CDS FAN NO. 3 FAN NO. 2 FAN NO. 1 FAN Cooling Fan Motor ECM FAN A/C Amplifier RF CF Radiator Fan Motor Engine Coolant Temperature Sensor A126792E01 1NZ-FXE COOLING – COOLING FAN SYSTEM CO–5 ON-VEHICLE INSPECTION HINT: It is normal for the cooling fan to sometimes rotate when the ignition switch is turned from ACC to ON. 1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURE (Below 83°C (181°F)) (a) Turn the ignition switch ON with the A/C switch OFF. (b) Check that the cooling fan stops. If it does not, check the cooling fan relay and engine coolant temperature sensor, and check if there is a disconnection or circuit open between them. (c) Disconnect the engine coolant temperature sensor connector. (d) Check that the cooling fan rotates. If it does not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short in the circuit between the cooling fan relay and engine coolant temperature sensor. (e) Reconnect the engine coolant temperature sensor connector. 2. CHECK COOLING FAN OPERATION AT HIGH TEMPERATURE (Above 93°C (199°F)) (a) Start the engine, and raise the coolant temperature to above 93°C (199°F). HINT: Coolant temperature is the value detected by the engine coolant temperature sensor on the cylinder head. (b) Check that the A/C switch is OFF. (c) Check that the cooling fan rotates. If it does not, check the fuses, cooling fan relay, ECM, cooling fan and engine coolant temperature sensor. 3. CHECK COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect the battery and an ammeter to the cooling fan. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 9.2 to 11.0 A (d) Reconnect the cooling fan connector. CO CO–6 1NZ-FXE COOLING – COOLANT COOLANT ON-VEHICLE INSPECTION 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. A088174E01 CO 1. REMOVE RADIATOR SUPPORT OPENING COVER (a) Remove the 6 clips and radiator support opening cover. 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE FRONT FENDER LINER LH (a) Remove the front part of the front fender liner LH. 4. DRAIN ENGINE COOLANT (a) Disconnect the coolant heat storage water pump connector. (b) Connect a vinyl hose to the drain cock of the radiator. (c) Connect a vinyl hose to the drain cock of the engine. (d) Connect a vinyl hose to the drain cock of the coolant heat storage tank. CAUTION: If the tank has any malfunctions, the tank surface becomes hot. To prevent injuries from burns, do not touch the tank. (e) Loosen the drain cock plugs of the radiator, engine and coolant heat storage tank, then drain the coolant. CAUTION: Even if the engine is cold, the coolant in the coolant heat storage tank is still hot. Be careful of the hot coolant when draining it. HINT: Record the amount of the drained coolant. It will be referred to when refilling the tank with coolant. CO–7 1NZ-FXE COOLING – COOLANT (f) Remove the radiator cap. Radiator Cap Engine Drain Cock Plug Drain Cock Plug Radiator Drain Cock Plug A124655E01 (g) Drain the coolant in the radiator reservoir. 5. ADD ENGINE COOLANT (a) Tighten the drain cock plug of the coolant heat storage tank, then disconnect the vinyl hose. (b) Tighten the drain cock plug of the engine, then disconnect the vinyl hose. Torque: 13 N*m (133 kgf*cm, 9.6 ft.*lbf) (c) Tighten the drain cock plug of the radiator, then disconnect the vinyl hose. (d) Connect a vinyl hose to the bleeder plug of the radiator assembly and the radiator reservoir. HINT: Insert the vinyl hose inside the radiator reservoir tank. Vinyl Hose A092991E01 A088678E01 (e) Using a 6 mm socket hexagon wrench, loosen the radiator bleeder plug from the radiator support service hole. (f) Fill the radiator with coolant up to the fill port. Standard capacity: 8.6 liters (9.1 US qts, 7.6 Imp. qts) HINT: • When filling coolant, press the radiator hose a few times. If the coolant level goes down, add more coolant. CO CO–8 1NZ-FXE COOLING – COOLANT • Amount of coolant to fill: Approximately 2.4 liters (2.5 US qts, 2.1 Imp. qts) • Use of improper coolants may damage the engine cooling system. • Only use "Toyota Super Long Life Coolant", or similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. • New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene-glycol concentration is approximately 50% and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended. • 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 more coolant. NOTICE: Never use water as a substitute for engine coolant. (g) Using a 6 mm socket hexagon wrench, tighten the radiator bleeder plug. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) (h) Install the radiator cop. (i) Fill the radiator reservoir tank with coolant to the full level. (j) Connect the coolant heat storage water pump connector. CO DLC3 A087542E02 A088678E01 (k) Connect the intelligent tester to the DLC3. (l) Turn the power switch ON (IG). (m) Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / WATER PUMP NOTICE: • The water pump motor operates for 30 seconds after WATER PUMP is ON in the ACTIVE TEST mode, then it automatically stops operating. • Do not actuate the water pump motor without coolant filled. (n) Using a 6 mm socket hexagon wrench, loosen the radiator bleeder plug from the radiator support service hole. (o) Remove the radiator cap, then fill the radiator with coolant up to the fill port. HINT: When filling coolant, press the radiator hose a few times. If the coolant level goes down, add more coolant. (p) Using a 6 mm socket hexagon wrench, tighten the radiator bleeder plug. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 1NZ-FXE COOLING – COOLANT CO–9 (q) Install the radiator cap. (r) Slowly pour coolant into the radiator reservoir until it reaches the full line. (s) Disconnect the vinyl hose between the bleeder plug of the radiator assembly and the radiator reservoir tank. (t) Set the vehicle to inspection mode (see page IN-5). (u) Warm up the engine until the thermostat is open. (v) Stop the engine, then wait until the coolant becomes cold. Remove the radiator cap and check the coolant level. CAUTION: If the engine or radiator is hot, do not remove the radiator cap. If the coolant level is lower, add coolant again. Warm up the engine, then check the coolant level. (w) When the coolant level stops going down, add coolant to the radiator reservoir tank up to the full level. 6. A088174E01 CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with engine coolant and attach a radiator cap tester. (b) Pump the tester to 137 kPa (1.4 kgf/cm2, 19.9 psi) and check for leakage. 7. INSTALL FRONT FENDER LINER LH 8. INSTALL ENGINE UNDER COVER LH 9. INSTALL RADIATOR SUPPORT OPENING COVER (a) Install the opening cover with the 6 clips. CO CO–10 1NZ-FXE COOLING – WATER PUMP WATER PUMP 1NZ-FXE COOLING ENGINE COMPONENTS GENERATOR V BELT x6 11 (112, 8) 11 (112, 8) 11 (112, 8) RADIATOR SUPPORT OPENING COVER 15 (153, 11) GASKET CO 11 (112, 8) 11 (112, 8) WATER PUMP PULLEY WATER PUMP ASSEMBLY ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124647E01 1NZ-FXE COOLING – WATER PUMP CO–11 REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. REMOVE GENERATOR V BELT (See page EM-6) 6. REMOVE ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (See page EM-32) 7. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley. SST 09960-10010 (09962-01000, 09963-00600) (b) Remove the 3 bolts and pump pulley. SST CO A092654E01 8. REMOVE WATER PUMP ASSEMBLY (a) Remove the 3 bolts and 2 nuts. (b) Remove the water pump and gasket. B009338E01 INSPECTION 1. A037047 INSPECT WATER PUMP ASSEMBLY (a) Visually check the water hole and air hole for coolant leakage. If leakage is found, replace the water pump assembly. (b) Turn the pulley, and check that the pump bearing moves smoothly and quietly. If it moves roughly or noisily, replace the water pump assembly. INSTALLATION SST A092654E01 1. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 2. INSTALL WATER PUMP PULLEY (a) Using SST, install the pump pulley with the 3 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) CO–12 1NZ-FXE COOLING – WATER PUMP 3. INSTALL ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (See page EM-38) 4. INSTALL GENERATOR V BELT (See page EM-6) 5. ADJUST GENERATOR V BELT (See page EM-6) 6. ADD ENGINE COOLANT (See page CO-7) 7. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 8. INSTALL ENGINE UNDER COVER RH 9. INSTALL ENGINE UNDER COVER LH 10. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) CO 1NZ-FXE COOLING – THERMOSTAT CO–13 THERMOSTAT 1NZ-FXE COOLING ENGINE COMPONENTS x6 RADIATOR SUPPORT OPENING COVER CO ENGINE UNDER COVER RH ENGINE UNDER COVER LH A127898E01 CO–14 1NZ-FXE COOLING – THERMOSTAT O-RING THERMOSTAT CO 9.0 (92, 80 in.*lbf) WATER INLET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124648E01 1NZ-FXE COOLING – THERMOSTAT CO–15 REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. REMOVE WATER INLET (a) Remove the 2 nuts and disconnect the water inlet from the cylinder block. 6. REMOVE THERMOSTAT (a) Remove the thermostat. (b) Remove the gasket from the thermostat. A086915E01 A088872E01 INSPECTION 1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. P013560E03 (a) Immerse the thermostat in water and then gradually heat the water. (b) Check the valve opening temperature of the thermostat. Standard valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. P000436E03 CO CO–16 1NZ-FXE COOLING – THERMOSTAT (c) Check the valve lift. Standard valve lift: 8.5 mm (0.338 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 temperature is below 77°C (171°F). If not fully closed, replace the thermostat. 8.5 mm A085445E03 INSTALLATION 1. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. A088873E01 CO 10° (b) Install the thermostat with the jiggle valve facing upward. HINT: The jiggle valve may be set within 10° of either side as shown in the illustration. 10° A081900E03 A086915E01 2. INSTALL WATER INLET (a) Install the water inlet to the cylinder block with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: Ensure that the gasket is not stuck between the water inlet and cylinder block. 3. ADD ENGINE COOLANT (See page CO-7) 4. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 5. INSTALL ENGINE UNDER COVER RH 6. INSTALL ENGINE UNDER COVER LH 7. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) CO–17 1NZ-FXE COOLING – FAN FAN 1NZ-FXE COOLING ENGINE COMPONENTS x6 Clip RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) 21 (214, 16) 20 (204, 15) COOLER BRACKET 5.0 (51, 44 in.*lbf) INVERTER BRACKET x5 x2 25 (255, 18) CO RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK ASSEMBLY HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124649E01 CO–18 1NZ-FXE COOLING – FAN 3.9 (40, 35 in.*lbf) 7.5 (76, 66 in.*lbf) 3.9 (40, 35 in.*lbf) FAN WITH MOTOR ASSEMBLY NO. 2 COOLING FAN MOTOR COOLING FAN MOTOR FAN 6.2 (63, 55 in.*lbf) CO 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) NO. 2 FAN RADIATOR SUPPORT UPPER LH NO. 2 INVERTER COOLING HOSE RADIATOR SUPPORT UPPER RH WIRE HARNESS RADIATOR INLET HOSE FAN MOTOR CONNECTOR RADIATOR OUTLET HOSE FAN CONNECTOR NO. 1 INVERTER COOLING HOSE TEMPERATURE SWITCH CONNECTOR HOSE CLAMP RADIATOR DRAIN COCK PLUG NO. 5 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 HEAT STORAGE WATER BY-PASS HOSE A127789E01 1NZ-FXE COOLING – FAN CO–19 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE ENGINE UNDER COVER LH 7. REMOVE ENGINE UNDER COVER RH 8. DRAIN ENGINE COOLANT (a) Drain the coolant in the radiator on the engine side (see page CO-6). (b) After draining the coolant in the radiator on the engine side, remove the radiator drain cock plug. (c) Drain the coolant in the radiator on the hybrid side (see page HX-58). 9. REMOVE FRONT BUMPER COVER (See page ET-4) 10. REMOVE FAN WITH MOTOR ASSEMBLY (a) Disconnect the connector and hose shown in the illustration. (b) After disconnecting the hose, remove the hose clamp. A086917E01 (c) Disconnect the hose shown in the illustration. (d) After disconnecting the hose, remove the 2 hose clamps. A086918E01 CO CO–20 1NZ-FXE COOLING – FAN (e) Disconnect the connector shown in the illustration. A086919E01 (f) Disconnect the hose shown in the illustration. A086920E01 CO (g) Disconnect the radiator outlet hose. (h) Disconnect the radiator reservoir hose. A086921E01 (i) Disconnect the inverter reservoir hose from the clamps. A086922E01 (j) Disconnect the radiator inlet hose. (k) Disconnect the connector and remove the clamp shown in the illustration. A086923E01 1NZ-FXE COOLING – FAN (l) CO–21 Remove the 3 bolts and inverter bracket. A086924E01 (m) Remove the 2 bolts and cooler bracket. A086925E01 (n) Disconnect the horn connector shown in the illustration. A086926E01 (o) Remove the 3 bolts, disconnect the hood lock control cable, and then remove the hood lock. A086927E01 (p) Remove the 5 bolts and radiator support. (q) Remove the hood lock control cable from the radiator support. A086928E01 CO CO–22 1NZ-FXE COOLING – FAN (r) Disconnect the wire harness clamps shown in the illustration. A086929E01 (s) Remove the 4 bolts, then remove the fan with motor from the vehicle. CO A086930E01 11. REMOVE FAN (a) Remove the nut and fan. 12. REMOVE NO. 2 FAN (a) Remove the nut and fan. 13. REMOVE COOLING FAN MOTOR (a) Remove the 3 bolts and fan motor. 14. REMOVE NO. 2 COOLING FAN MOTOR (a) Remove the 3 bolts and fan motor. A128250 INSTALLATION A128250 1. INSTALL COOLING FAN MOTOR (a) Install the fan motor with the 3 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 2. INSTALL NO. 2 COOLING FAN MOTOR (a) Install the fan motor with the 3 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 1NZ-FXE COOLING – FAN CO–23 3. INSTALL FAN (a) Install the fan with the nut. Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 4. INSTALL NO. 2 FAN (a) Install the fan with the nut. Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 5. INSTALL FAN WITH MOTOR ASSEMBLY (a) Set the fan with motor to the vehicle, then install it with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) CO A086930E01 (b) Connect the 2 wire harness clamps shown in the illustration. A086929E01 (c) Install the hood lock control cable to the radiator support. (d) Install the radiator support with the 5 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A086928E01 CO–24 1NZ-FXE COOLING – FAN (e) Connect the hood lock control cable to the hood lock. (f) Install the hood lock with the 3 bolts (see page ED5). A092969E01 (g) Connect the horn connector shown in the illustration. A086926E01 CO (h) Install the cooler bracket with the 2 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) for bolt A Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt B B A A092519E01 (i) Install the inverter bracket with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) for bolt A Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B B B A A089867E01 (j) Connect the connector and install the clamp. (k) Connect the radiator inlet hose. A086923E01 1NZ-FXE COOLING – FAN (l) CO–25 Connect the inverter reservoir hose to each clamp. A086922E01 (m) Connect the radiator reservoir hose. (n) Connect the radiator outlet hose. A086921E01 (o) Connect the hose shown in the illustration. A086920E01 (p) Connect the connector shown in the illustration. A086919E01 (q) Install the 2 hose clamps to the fan shroud. (r) Connect the hose shown in the illustration. A086918E01 CO CO–26 1NZ-FXE COOLING – FAN (s) Install the hose clamp to the fan shroud. (t) Connect the hose and connector shown in the illustration. 6. INSTALL FRONT BUMPER COVER (See page ET-6) 7. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) A086917E01 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. ADD ENGINE COOLANT (a) Fill the radiator on the hybrid side with coolant (see page HX-58). (b) Fill the radiator on the engine side with coolant (see page CO-7). CO 12. CHECK FOR ENGINE COOLANT LEAKS (a) Check the cooling system on the hybrid side for coolant leaks. (b) Check the cooling system on the engine side for coolant leaks (see page CO-9). 13. INSTALL ENGINE UNDER COVER RH 14. INSTALL ENGINE UNDER COVER LH 15. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 16. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal. CO–27 1NZ-FXE COOLING – COOLING FAN RELAY COOLING FAN RELAY ON-VEHICLE INSPECTION 1. INSPECT INTEGRATION RELAY (UNIT C: NO. 1 FAN (FAN NO. 1) RELAY) (a) Inspect the resistance of the fan relay. (1) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 3G-1- 3G-4 10 kΩ or higher 3G-1- 3G-4 Below 1 Ω (apply battery voltage to terminals 3G-2 and 3G-3) 3G 8 76 5 CO 4 32 1 A129013E01 If the resistance is not as specified, replace the integration relay. 2. 1 4 2 4 3 5 5 1 2 3 INSPECT NO. 2 FAN RELAY (Marking: FAN NO. 2) (a) Remove the relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A087121E01 If the result is not as specified, replace the relay. (c) Install the relay. CO–28 1NZ-FXE COOLING – COOLING FAN RELAY 3. 3 5 1 2 5 1 2 3 B060778E46 CO INSPECT NO. 3 FAN RELAY (Marking: FAN NO. 3) (a) Remove the relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (c) Install the relay. CO–29 1NZ-FXE COOLING – RADIATOR RADIATOR 1NZ-FXE COOLING ENGINE COMPONENTS x6 Clip RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) 21 (214, 16) 20 (204, 15) COOLER BRACKET 5.0 (51, 44 in.*lbf) INVERTER BRACKET x5 x2 25 (255, 18) CO RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK ASSEMBLY HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124649E01 CO–30 1NZ-FXE COOLING – RADIATOR 7.5 (76, 66 in.*lbf) FAN ASSEMBLY WITH MOTOR 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) CO RADIATOR SUPPORT UPPER RH RADIATOR SUPPORT UPPER LH NO. 2 INVERTER COOLING HOSE WIRE HARNESS RADIATOR INLET HOSE FAN MOTOR CONNECTOR RADIATOR OUTLET HOSE FAN CONNECTOR NO. 1 INVERTER COOLING HOSE TEMPERATURE SWITCH CONNECTOR HOSE CLAMP RADIATOR DRAIN COCK PLUG NO. 5 INVERTER COOLING HOSE NO. 1 HEAT STORAGE WATER BY-PASS HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124650E01 CO–31 1NZ-FXE COOLING – RADIATOR RADIATOR FAN TEMPERATURE SWITCH NO. 2 RADIATOR ASSEMBLY CO 3.9 (40, 35 in.*lbf) RADIATOR SUPPORT LOWER RH 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124651E01 CO–32 1NZ-FXE COOLING – RADIATOR ON-VEHICLE INSPECTION 1. 1 4 2 ) 3 A110260 (5) Pump the cap tester several times, and check the maximum pressure*. NOTICE: When using the cap tester, keep the tester at an angle of 30° or more above horizontal. Pumping speed: 1 pump per second *: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment criterion Radiator Cap Tester 30°or more Radiator Cap CO CHECK RADIATOR CAP SUB-ASSEMBLY (a) Measure the valve opening pressure. (1) If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean the part(s) with water and finger scouring. (2) Check that 1, 2 or 3 is not deformed, cracked or swollen. (3) Check that 3 and 4 are not stuck together. (4) Apply engine coolant to 2 and 3 before using the radiator cap tester. A085446E01 Item Specified Condition Standard value (for brand-new cap) 93.3 to 122.7 kPa (0.95 to 1.25 kgf/ Minimum standard value (after using cap) 78.5 kPa (0.8 kgf/cm2, 11.4 psi) cm2, 13.5 to 17.8 psi) If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. ON-VEHICLE CLEANING 1. A099252E02 CHECK FINS FOR BLOCKAGE (a) Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the hose connections. If the fins are blocked, wash them with water or a steam cleaner. NOTICE: • If the distance between the steam cleaner and core is too close, the fins may be damaged. • Keep the following injection distance. Standard injection distance Injection Pressure Specified Condition 2,942 to 4,903 kPa 300 mm (11.81 in.) (30 to 50 kgf/cm2, 427 to 711 psi) 4,903 to 7,845 kPa 500 mm (19.69 in.) (50 to 80 kgf/cm2, 711 to 1,138 psi) • If the fins are bent, straighten them with a screwdriver or pliers. • Never apply water directly onto the electronic components. (b) Dry the fins with compressed air. 1NZ-FXE COOLING – RADIATOR CO–33 REMOVAL 1. REMOVE FAN ASSEMBLY WITH MOTOR (a) Remove the fan with motor (see page CO-19). 2. REMOVE NO. 2 RADIATOR ASSEMBLY (a) Remove the 3 bolts and radiator support upper RH. (b) Remove the 3 bolts and radiator support upper LH. (c) Remove the 3 bolts and radiator support lower RH. (d) Remove the 3 bolts and radiator support lower LH. (e) Remove the No. 2 radiator from the vehicle. CO A086932E01 3. REMOVE RADIATOR FAN TEMPERATURE SWITCH (a) Using SST, remove the radiator fan temperature switch. SST 09817-33190 SST A086933E01 INSTALLATION 1. SST A086933E01 INSTALL RADIATOR FAN TEMPERATURE SWITCH (a) Using SST, install the radiator fan temperature switch. SST 09817-33190 Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) CO–34 1NZ-FXE COOLING – RADIATOR 2. INSTALL NO. 2 RADIATOR ASSEMBLY (a) Install the No. 2 radiator to the vehicle. (b) Install the radiator support lower LH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (c) Install the radiator support lower RH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (d) Install the radiator support upper LH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (e) Install the radiator support upper RH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 3. INSTALL FAN ASSEMBLY WITH MOTOR (a) Install the fan with motor (see page CO-22). A A A A B B B A B A A A A086934E01 CO CO–35 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK COOLANT HEAT STORAGE TANK 1NZ-FXE COOLING ENGINE COMPONENTS CLIP x6 RADIATOR SUPPORT OPENING COVER COOLANT HEAT STORAGE TANK ASSEMBLY FRONT BUMPER COVER 19 (194, 14) FRONT FENDER LINER LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE x2 x2 19 (194, 14) 19 (194, 14) NO. 1 HEAT STORAGE WATER BY-PASS HOSE DRAIN COCK PLUG ENGINE UNDER COVER RH WATER PUMP CONNECTOR TEMPERATURE SENSOR CONNECTOR ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124653E01 CO CO–36 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK REMOVAL CAUTION: • Before and after the procedure, be sure to check DTCs and confirm that no DTCs are output. • If the tank has any malfunctions, the tank surface becomes hot. To prevent injuries from burns, do not touch the tank. • The coolant heat storage tank assembly is prohibited from being disassembled and can be disassembled only as instructed. 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE ENGINE UNDER COVER LH 7. REMOVE ENGINE UNDER COVER RH 8. REMOVE FRONT BUMPER COVER (See page ET-4) 9. REMOVE FRONT FENDER LINER LH (a) Partially remove the front fender liner LH. CO 10. DRAIN ENGINE COOLANT (a) Loosen the drain cock plug, then drain the coolant. CAUTION: Even if the engine is cold, the coolant in the coolant heat storage tank is still hot. Be careful of the hot coolant when draining it. A086936E01 11. REMOVE COOLANT HEAT STORAGE TANK ASSEMBLY (a) Disconnect the 2 hoses. A087327E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK CO–37 (b) Disconnect the water pump motor and temperature sensor connectors. A086935E01 (c) Remove the nut and 4 bolts. NOTICE: The coolant heat storage tank bracket can be easily bent. Hold the coolant heat storage tank tightly when removing the nut and bolts. CO A087328E01 (d) Separate the stud bolt and 2 claws shown in the illustration, then remove the coolant heat storage tank. Stud Bolt Claw Claw A087329E01 CO–38 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK INSTALLATION 1. Insert Stud Bolt Stud Bolt INSTALL COOLANT HEAT STORAGE TANK ASSEMBLY (a) Insert the 2 claws shown in the illustration to the vehicle side, then insert the stud bolt to the vehicle side. NOTICE: The coolant storage tank bracket can be easily bent. Hold the coolant storage tank tightly when inserting the claws and stud bolt. Insert Claws Claws Claws A087330E02 CO (b) Install the 4 bolts and nut. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: • When tightening bolt 1 and 2, push the coolant heat storage tank bracket to the vehicle front. • The coolant heat storage tank bracket can be easily bent. Hold the coolant heat storage tank tightly when installing the bolts and nut. 5 3 1 4 2 A087331E01 (c) Connect the water pump motor and temperature sensor connectors. A086935E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK CO–39 (d) Connect the 2 hoses shown in the illustration. 2. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. ADD ENGINE COOLANT (See page HX-58) 7. CHECK FOR ENGINE COOLANT LEAKS 8. INSTALL FRONT FENDER LINER LH 9. INSTALL FRONT BUMPER COVER (See page ET-6) A087327E01 10. INSTALL ENGINE UNDER COVER RH 11. INSTALL ENGINE UNDER COVER LH 12. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 13. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal. CO CO–40 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP COOLANT HEAT STORAGE WATER PUMP 1NZ-FXE COOLING ENGINE COMPONENTS CLIP x6 RADIATOR SUPPORT OPENING COVER CO ENGINE UNDER COVER LH FRONT FENDER LINER LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE x2 x4 x3 COOLANT HEAT STORAGE WATER PUMP WATER BY-PASS HOSE 6.0 (61, 53 in.*lbf) WATER PUMP CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque A124652E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP CO–41 REMOVAL 1. REMOVE REAR FLOOR NO. 2 BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR FLOOR NO. 3 BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE FRONT WHEEL LH 7. REMOVE ENGINE UNDER COVER LH 8. REMOVE FRONT FENDER LINER LH (a) Partially remove the front fender liner LH. 9. DRAIN ENGINE COOLANT (See page HX-58) 10. REMOVE COOLANT HEAT STORAGE WATER PUMP (a) Disconnect the coolant heat storage water pump connector. (b) Disconnect the 2 hoses. A087332E01 (c) Remove the bolt and coolant heat storage water pump. A087333E01 CO CO–42 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP INSTALLATION 1. INSTALL COOLANT HEAT STORAGE WATER PUMP (a) Install the coolant heat storage pump water pump with the bolt. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A087333E01 (b) Connect the 2 hoses. (c) Connect the connector to the coolant heat storage pump. 2. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 3. INSTALL REAR FLOOR NO. 3 BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR FLOOR NO. 2 BOARD (See page CH8) 6. ADD ENGINE COOLANT (See page HX-58) 7. CHECK FOR ENGINE COOLANT LEAKS 8. INSTALL FRONT FENDER LINER LH 9. INSTALL ENGINE UNDER COVER LH A087332E01 CO 10. INSTALL FRONT WHEEL LH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 11. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.