2AZ-FE COOLING – COOLING SYSTEM CO–1

COOLING SYSTEM
ON-VEHICLE INSPECTION
1. CHECK FOR ENGINE COOLANT LEAKS
NOTICE:
Before performing each inspection, turn the A/C
switch OFF.
CAUTION:
A135234 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 a radiator cap tester, increase the pressure
inside the radiator to 118 kPa (1.2 kgf*cm, 17 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 heater core, cylinder block and cylinder
head.
2. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR
(a) Check that the engine coolant level is between the
LOW and FULL lines when the engine is cold.
If the engine coolant level is 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 to the FULL line.
NOTICE:
Do not substitute plain water for engine coolant.
3. INSPECT ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CO
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 any excessive deposits of rust or
scales around the radiator cap and radiator filler
hole. Also, the coolant should be free of oil.
If excessively dirty, clean the coolant passage and
replace the coolant.
(c) Install the radiator cap.
 CO–2 2AZ-FE COOLING – COOLING FAN SYSTEM

COOLING FAN SYSTEM

2AZ-FE COOLING
ENGINE

PARTS LOCATION

COOLING FAN MOTOR

ENGINE ROOM RELAY BLOCK

INSTRUMENT PANEL JUNCTION BLOCK
CO -COOLING FAN RELAY

-CDS FAN FUSE -ECU IG FUSE NO. 1

-RDI FAN FUSE

A137456E02
 2AZ-FE COOLING – COOLING FAN SYSTEM CO–3

SYSTEM DIAGRAM

ECM
FAN No. 1

From Battery
RDI FAN 3 5
22
From A24 FANH
Ignition Switch ECU IG No. 1
1 2
From Battery
CDS FAN

A6 A7
A/C Condenser 2 Radiator
Fan Motor Fan Motor
FAN No. 3 4 FAN No. 2
1

5 3 2 1 3 5

1 2 1 2

21
A24 FANL

A137000

CO
 CO–4 2AZ-FE COOLING – COOLING FAN SYSTEM

ON-VEHICLE INSPECTION
1. INSPECT COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 83°C (181°F))
(a) Turn the ignition switch to the ON position.
(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 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 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.

CO
 2AZ-FE COOLING – COOLANT CO–5

COOLANT
ON-VEHICLE INSPECTION
1. REMOVE FRONT WHEEL OPENING EXTENSION
PAD RH
2. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. DRAIN ENGINE COOLANT
NOTICE:
Do not remove the radiator cap sub-assembly while
the engine and radiator are still hot. Pressurized, hot
engine coolant and steam may be released and
cause serious burns.
(a) Remove the radiator cap sub-assembly from the
radiator assembly.
(b) Loosen the radiator drain cock plug and cylinder
block drain cock plug, then drain the coolant.

Radiator Cap

CO

Cylinder Block Drain

Cock Plug

Radiator Drain Cock Plug

A136224E04

HINT:
Collect the coolant in a container and dispose of it
according to the regulations in your area.
6. ADD ENGINE COOLANT
(a) Close the radiator drain cock plug and 2 cylinder
block drain cock plugs.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for
cylinder block drain cock plug
 CO–6 2AZ-FE COOLING – COOLANT

(b) Slowly fill the radiator with TOYOTA Super Long Life
Coolant (SLLC).
Specified capacity:
6.2 liters (6.6 US qts, 5.5 lmp. qts)
HINT:
• 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).
• Contact your TOYOTA dealer for further details.
(c) Slowly pour coolant into the radiator reservoir tank
until it reaches the FULL line.
(d) Press the inlet and outlet radiator hoses several
times by hand, and then check the level of the
coolant.
If the coolant level is low, add coolant.
(e) Install the radiator cap sub-assembly and reservoir
tank cap.
(f) Start the engine, and warm it up.
HINT:
Adjust the air conditioner set temperature to MAX
(HOT).
(g) Stop the engine, and wait until the engine coolant
cools down.
(h) Add engine coolant to the FULL line on the radiator
reservoir.
7. CHECK FOR ENGINE COOLANT LEAKS
CO 8. INSTALL ENGINE UNDER COVER RH
9. INSTALL ENGINE UNDER COVER LH
10. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH
11. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
 2AZ-FE COOLING – WATER PUMP CO–7

WATER PUMP
2AZ-FE COOLING
ENGINE

COMPONENTS

64 (653, 47)

ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

52 (531, 38)

64 (653, 47) NO. 2 ENGINE MOUNTING BRACKET RH

NO. 2 ENGINE
MOUNTING STAY RH

V-RIBBED BELT

9.8 (100, 7 )
8.4 (86, 74 in.*lbf)

52 (530, 38)

21 (215, 16)

CO
GENERATOR ASSEMBLY

ENGINE UNDER COVER RH

FRONT FENDER
APRON SEAL RH
ENGINE UNDER COVER LH

FRONT WHEEL OPENING

EXTENSION PAD LH
FRONT WHEEL OPENING
EXTENSION PAD RH
N*m (kgf*cm, ft.*lbf) : Specified torque
A136149E02
 CO–8 2AZ-FE COOLING – WATER PUMP

CLAMP BRACKET

9.0 (92, 80 in.*lbf)

9.0 (92, 80 in.*lbf)

26 (265, 19)
26 (265, 19)

WATER PUMP PULLEY WATER PUMP ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

A136759E05

CO
 2AZ-FE COOLING – WATER PUMP CO–9

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FRONT WHEEL OPENING EXTENSION
PAD RH
3. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. DRAIN ENGINE COOLANT (See page CO-5)
7. REMOVE FRONT FENDER APRON SEAL RH
8. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See
page EM-95)
9. REMOVE ENGINE MOVING CONTROL ROD SUB-
ASSEMBLY (See page EM-95)
10. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
(See page EM-96)
11. REMOVE V-RIBBED BELT (See page EM-6)
12. REMOVE GENERATOR ASSEMBLY (See page CH-11)
13. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST SST 09960-10010 (09962-01000, 09963-00700)

A098715E03 CO
14. REMOVE WATER PUMP ASSEMBLY
(a) Remove the clamp of the crankshaft position sensor
from the water pump.
(b) Disconnect the wire of the crankshaft position
sensor from the clamp bracket.

A094516E01
 CO–10 2AZ-FE COOLING – WATER PUMP

(c) Remove the 4 bolts, 2 nuts and clamp bracket.

Clamp Bracket

B012052E03

(d) Using a screwdriver, pry between the water pump

and cylinder block, and then remove the water
pump.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surfaces of
the water pump and cylinder block.

A129792

INSPECTION
Air Hole
Drain Hole 1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole and air hole for coolant
leakage.
If leakage is found, replace the water pump
assembly.

A128603E01

(b) Turn the pulley, and then check that the water pump
bearing moves smoothly without making a "click"
CO sound.
If it does not move smoothly, replace the water
pump assembly.

A112198
 2AZ-FE COOLING – WATER PUMP CO–11

INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the
contact surface.
(b) Apply a continuous line of seal packing as shown in
the illustration.
Seal Diameter Seal packing:
Toyota Genuine Seal Packing Black, Three
2.2 to 2.5 mm Bond 1207B or Equivalent
(0.09 to 0.10 in.) A A Standard seal diameter:
2.2 to 2.5 mm (0.09 to 0.10 in.)
NOTICE:
• Remove any oil from the contact surface.
• The parts must be set within 3 minutes after
applying seal packing. Otherwise, the
material must be removed and reapplied.

A-A
0.5 to 1.0 mm
(0.02 to 0.04 in.)

2.5 mm (0.10 in.)

A094495E05

(c) Install the water pump and clamp bracket with the 4
bolts and 2 nuts.
Clamp Bracket Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

CO
B012052E03

(d) Install the wire of the crankshaft position sensor

onto the clamp bracket.
(e) Install the clamp of the crankshaft position sensor
onto the water pump.

A094516
 CO–12 2AZ-FE COOLING – WATER PUMP

2. INSTALL WATER PUMP PULLEY

(a) Using SST, install the water pump pulley with the 4
bolts.
SST
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
3. INSTALL GENERATOR ASSEMBLY (See page CH-19)
4. INSTALL V-RIBBED BELT (See page EM-6)
5. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
A098715E02
(See page EM-118)
6. INSTALL ENGINE MOVING CONTROL ROD SUB-
ASSEMBLY (See page EM-119)
7. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See
page EM-119)
8. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL (See page EM-120)
9. ADD ENGINE COOLANT (See page CO-5)
10. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
11. INSTALL ENGINE UNDER COVER LH
12. INSTALL ENGINE UNDER COVER RH
13. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
14. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH

CO
 CO–12 2AZ-FE COOLING – THERMOSTAT

THERMOSTAT
2AZ-FE COOLING
ENGINE

COMPONENTS

WATER INLET THERMOSTAT

9.0 (92, 80 in.*lbf)

GASKET

RADIATOR HOSE OUTLET

Non-reusable part

CO N*m (kgf*cm, ft.*lbf) : Specified torque

A134970E03
2AZ-FE COOLING – THERMOSTAT CO–13

REMOVAL
1. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
2. REMOVE FRONT WHEEL OPENING EXTENSION
PAD RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. DRAIN ENGINE COOLANT (See page CO-5)
6. DISCONNECT RADIATOR HOSE OUTLET (See page
EM-96)
7. REMOVE WATER INLET
(a) Remove the 2 nuts and disconnect the water inlet
from the cylinder block.
8. REMOVE THERMOSTAT
(a) Remove the gasket from the thermostat.

A112181

INSPECTION
1. INSPECT THERMOSTAT
(a) The valve opening temperature is inscribed on the
thermostat.

P013560E01

(b) Immerse the thermostat in water, and then gradually

CO
heat the water.
(c) 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.

P000436E01
 CO–14 2AZ-FE COOLING – THERMOSTAT

(d) Check the valve lift.

Standard 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.
(e) Check that the valve is fully closed when the
thermostat is at low temperatures (below 77°C
Valve Lift (171°F)).
If it is not fully closed, replace the thermostat.
A085445E04

CO
 2AZ-FE COOLING – THERMOSTAT CO–15

INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve upward.
Upward HINT:
The jiggle valve may be set to within 10° on either
10° 10°
side of the prescribed position.

Jiggle Valve

A112199E02

2. INSTALL WATER INLET

(a) Install the water inlet with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. CONNECT RADIATOR HOSE OUTLET (See page EM-
118)
4. ADD ENGINE COOLANT (See page CO-5)
5. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
A112181

6. INSTALL ENGINE UNDER COVER LH

7. INSTALL ENGINE UNDER COVER RH
8. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH
9. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH

CO
 2AZ-FE COOLING – COOLING FAN MOTOR CO–15

Cooling Fan Motor Side Connector: COOLING FAN MOTOR

ON-VEHICLE INSPECTION
1. COOLING FAN MOTOR
(a) Check that the motor turns smoothly when the
battery is connected to the fan motor connector.
(b) Measure the current while the motor is turning.
Positive (+) Negative (-) Standard current:
A103699E02 With trailer hitch:
11.8 to 14.8 A at 20°C (68°F)
Without trailer hitch:
7.9 to 10.9 A at 20°C (68°F)
If the result is not as specified, replace the cooling
fan motor.
2. NO. 2 COOLING FAN MOTOR
Cooling Fan Motor Side Connector:
(a) Check that the motor turns smoothly when the
battery is connected to the fan motor connector.
(b) Measure the current while the motor is turning.
Standard current:
With trailer hitch:
7.9 to 10.9 A at 20°C (68°F)
Without trailer hitch:
Positive (+) Negative (-) 7.9 to 10.9 A at 20°C (68°F)
A103699E02 If the result is not as specified, replace the cooling
fan motor No. 2.

CO
 CO–16 2AZ-FE COOLING – COOLING FAN RELAY

COOLING FAN RELAY

1 2
ON-VEHICLE INSPECTION
5 3 1. COOLING FAN RELAY
5 (a) Remove the relay from the engine room No. 2 relay
1 2 block.
3 (b) Measure the resistance of the relay.
Standard resistance
B060778E01
Tester Connection Specified Condition
3-5 10 Ω 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 to the engine room relay block No.
2.
2. COOLING FAN RELAY NO. 2
1 4 2 (a) Remove the relay from the engine room No. 2 relay
4 block.
(b) Measure the resistance of the relay.
3 5 Standard resistance
5 Tester Connection Specified Condition

1 2 3-4 Below 1 Ω
3 3-5 10 Ω or higher
3-4 10 Ω or higher
A087121E01
(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)

If the result is not as specified, replace the relay.

(c) Install the relay.
CO 3. COOLING FAN RELAY NO. 3
(a) Remove the relay from the engine room No. 2 relay
block.
1 2 (b) Measure the resistance of the relay.
3 5 Standard resistance
5 Tester Connection Specified Condition
1 2 3-5 10 Ω or higher
3 3-5 Below 1 Ω
(when battery voltage is applied to
B060778E45 terminals 1 and 2)

If the result is not as specified, replace the relay.

(c) Install the relay.
 2AZ-FE COOLING – RADIATOR CO–17

RADIATOR
2AZ-FE COOLING
ENGINE

COMPONENTS

AIR CLEANER CAP SUB-ASSEMBLY

5.0 (51, 44 in.*lbf) AIR CLEANER FILTER ELEMENT

x2

AIR CLEANER INLET ASSEMBLY

CO

ENGINE UNDER COVER RH

ENGINE UNDER COVER LH

FRONT WHEEL OPENING

EXTENSION PAD RH
FRONT WHEEL OPENING
EXTENSION PAD LH

N*m (kgf*cm, ft.*lbf) : Specified torque

A139342E01
 CO–18 2AZ-FE COOLING – RADIATOR

7.0 (71, 62 in.*lbf)

x4 RADIATOR SUPPORT UPPER

HOOD LOCK ASSEMBLY

x2
7.5 (77, 66 in.*lbf)

HORN CONNECTOR

7.0 (71, 62 in.*lbf)

7.5 (77, 66 in.*lbf)

x2
x2

CO
FRONT BUMPER
ENERGY ABSORBER

x2

x9

FRONT BUMPER ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

A134969E02
 2AZ-FE COOLING – RADIATOR CO–19

RADIATOR HOSE OUTLET

RADIATOR HOSE INLET

RADIATOR SUPPORT
CUSHION

RADIATOR ASSEMBLY
FAN MOTOR
CONNECTOR

FAN MOTOR WITH MOTOR

RADIATOR SUPPORT
LOWER

5.0 (51, 44 in.*lbf)

CO

x4

CONDENSER ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

A134972E02
 CO–20 2AZ-FE COOLING – RADIATOR

RADIATOR CAP SUB-ASSEMBLY

FAN ASSEMBLY
RADIATOR TANK UPPER WITH MOTOR

O-RING

CORE SUB-
ASSEMBLY 15 (150, 11)

with AUTOMATIC TRANSAXLE

O-RING 15 (150, 11)

OIL COOLER
O-RING
ASSEMBLY

O-RING OIL COOLER PIPE

RADIATOR TANK LOWER DRAIN PLUG 8.3 (85, 73 in.*lbf)

O-RING
Non-reusable part

N*m (kgf*cm, ft.*lbf) : Specified torque

A137802E02

ON-VEHICLE INSPECTION
CO 1. CHECK RADIATOR CAP SUB-ASSEMBLY
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on
1
rubber packings 1, 2 or 3, clean the part(s) with
2
water and finger scouring.
(2) Check that rubber packings 1, 2 and 3 are not
3 4 deformed, cracked or swollen.
A107446E01
(3) Check that rubber packings 3 and 4 are not
stuck together.
(4) Apply engine coolant to rubber packings 2 and
3 before using the radiator cap tester.
(5) When using the cap tester, tilt it to 30° or more
above the horizontal.
 2AZ-FE COOLING – RADIATOR CO–21

(6) Pump the cap tester several times, and check

the maximum pressure *1.
Radiator Cap Tester Pumping speed:
1 pumps every second
*1: Even if the cap cannot maintain the
maximum pressure, it is not a defect.
30° or more Judgment Criteria
Radiator Cap Item Specified Condition
Standard valve 93.3 to 122.7 kPa (0.95 to 1.25 kgf/
A104601E03
(for brand-new cap) cm2, 13.5 to 17.8 psi)
Minimum standard valve
(after using cap) 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.
ON-VEHICLE CLEANING
1. INSPECT FINS BLOCKAGE
(a) If the fins are clogged, wash them with water or a
steam cleaner. Dry with compressed air.
NOTICE:
• If the distance between the steam cleaner and
the core is too close, the fins may become
damaged. Keep the following injection
A073603
distance.
Standard
Injection Distance Injection Pressure
2,942 to 4,903 kPa
300 mm (11.81 in.)
(30 to 50 kg/cm2, 427 to 711 psi)
4,903 to 7,845 kPa
500 mm (19.69 in.)
(50 to 80 kg/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
CO
components.
 CO–22 2AZ-FE COOLING – RADIATOR

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
3. REMOVE FRONT WHEEL OPENING EXTENSION
PAD RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-416)
7. REMOVE AIR CLEANER INLET ASSEMBLY (See
page EM-94)
8. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog
Light) (See page ET-5)
9. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog
Light) (See page ET-6)
10. REMOVE FRONT BUMPER ENERGY ABSORBER
11. SEPARATE RADIATOR RESERVE TANK HOSE
(a) Separate the radiator reserve tank hose from the
radiator assembly.

A135233

12. DISCONNECT RADIATOR HOSE INLET

CO (a) Disconnect the radiator hose inlet from the radiator
assembly.

A135240

13. DISCONNECT RADIATOR HOSE OUTLET

(a) Disconnect the radiator hose outlet from the radiator
assembly.

A133364
2AZ-FE COOLING – RADIATOR CO–23

14. DISCONNECT OIL COOLER INLET HOSE (for

Automatic Transaxle)
(a) Disconnect the oil cooler inlet hose from the radiator
assembly.

A133365

15. DISCONNECT OIL COOLER OUTLET HOSE (for

Automatic Transaxle)
(a) Disconnect the oil cooler outlet hose from the
radiator assembly.

A133366

16. REMOVE RADIATOR SUPPORT UPPER

(a) Disconnect the horn connector.
(b) Remove the 3 bolts and separate the hood lock
assembly from the radiator support upper.

A135235

(c) Remove the clamp and separate the hood lock

control cable from the radiator support upper. CO

A135236

(d) Remove the 5 bolts and radiator support upper.

A135237
 CO–24 2AZ-FE COOLING – RADIATOR

17. REMOVE RADIATOR ASSEMBLY

(a) Remove the 3 clamps and 2 connectors.

A135241

(b) Remove the 4 bolts and separate the condenser

assembly from the radiator assembly.

A135239

(c) Remove the radiator assembly from the body.

A135238

18. REMOVE FAN ASSEMBLY WITH MOTOR

CO (a) Release the 3 snap fits and lift the fan assembly
with motor from the radiator.

Guide

Snap Fit
A136226E01

19. REMOVE RADIATOR SUPPORT CUSHION

(a) Remove the 2 radiator support cushions from the
radiator assembly.

Radiator Support Cushion

A133371E02
 2AZ-FE COOLING – RADIATOR CO–25

20. REMOVE RADIATOR SUPPORT LOWER

(a) Remove the 2 radiator support lowers from the
Radiator Support Lower radiator assembly.

A133371E03

CO
 CO–26 2AZ-FE COOLING – RADIATOR

DISASSEMBLY
1. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O-ring.
2. REMOVE RADIATOR TANK UPPER
(a) Install the claw to the overhaul handle, inserting it in
Stopper Bolt
the hole in part A as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
Part A (b) While gripping the handle, adjust the stopper bolt so
Dimension B that dimension B is as shown in the illustration.
Dimension B:
0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTICE:
If the stopper bolt is not adjusted, the claw may
be damaged.
0.2 to 0.3 mm
SST

Claw
Overhaul Handle

A104619E05

(c) Using SST to release the caulking, grip the handle

until stopped by the stopper bolt.
Tank SST 09230-01010 (09231-01010, 09231-01030)

Lock Plate
SST
CO
Stopper Bolt
A128137E02

(d) Lightly tap the bracket of the radiator (or radiator

hose inlet or outlet) with a soft-faced hammer and
remove the tank.
(e) Remove the O-ring.
Tap 3. REMOVE RADIATOR TANK LOWER
HINT:
Removal procedure of the radiator tank lower is the
same as that of the radiator tank upper.
A128138E01
 2AZ-FE COOLING – RADIATOR CO–27

4. REMOVE OIL COOLER ASSEMBLY

(A) (a) Remove the screw and cooler pipe (A).
(D) (C) (b) Remove the nut and plate washer (B).
(A) (c) Remove the oil cooler (C).
(d) Remove the 2 O-rings from the oil cooler (D).
(B)

Lower (B)
(C)
Tank

A128140E02

Lock Plate Lock Plate

INSPECTION
1. INSPECT LOCK PLATE
(a) Inspect the 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 the shape of
the lock plate groove with pliers or a similar
Core
A087087E06
object, if necessary.
• Water leakage will result if the bottom of the lock
plate groove is damaged or dented. Repair or
replace the lock plate if necessary.
NOTICE:
The radiator can only be recaulked 2 times, After
recaulking 2 times, the radiator core must be
replaced.
REASSEMBLY
(A) 1. INSTALL OIL COOLER ASSEMBLY
(D) (C)
(a) Clean the O-ring contact surfaces of the lower tank
(A) and oil cooler (D).
(B) (b) Install 2 new O-rings to the oil cooler (C).
(B)
(c) Install the oil cooler to the lower tank.
Lower
Tank
(C) (d) Install the plate washer and nut (B).
Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
CO
A128140E02
(e) Install the cooler pipe (A).
Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
(f) Install the screw (A).
 CO–28 2AZ-FE COOLING – RADIATOR

2. INSTALL RADIATOR TANK UPPER

Stopper Bolt (a) Install the punch assembly to the overhaul handle,
inserting it in the hole in part A as shown in the
Part A illustration.
SST 09230-01010, 09231-14010
Dimension B (b) While gripping the handle, adjust the stopper bolt so
that dimension B is as shown in the illustration.
Dimension B:
8.4 mm (0.331 in.)

SST

Punch Assembly
Overhaul Handle

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(c) 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
○ Normal X Twisted with sand paper without scratching it.

CO

X Twisted
O-Ring

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(d) Install the tank without damaging the O-ring.

CORRECT
(e) Tap the lock plate with a soft-faced hammer so that
there is no gap between the lock plate and the tank.
Tank

WRONG

Lock
Tap Plate

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 2AZ-FE COOLING – RADIATOR CO–29

(f) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few
5 3 7
times, fully caulk the lock plate by gripping the
1 2 handle until stopped by the stopper plate.
HINT:
6 4 8 • Do not tap the areas protruding around the pipes,
brackets or tank ribs.
• The dotted circles shown in the illustration and
SST parts of the oil cooler near the dotted circles
Lock Plate cannot be tapped with the SST. Use pliers or
Stopper similar objects and be careful not to damage the
Bolt Tank core plates.

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(g) Check the lock plate height (H) after completing

caulking.
Plate height (H):
H 7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If not within the specified height range, adjust the
stopper bolt of the handle and caulk again.
3. INSTALL RADIATOR TANK LOWER
SST 09230-01010, 09231-14010
HINT:
A128142E02
Removal procedure of the lower radiator tank is the
same as that of the upper radiator tank.
4. INSTALL DRAIN PLUG CO
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.
5. INSPECT FOR WATER LEAKS
(a) Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230-01010
(b) Using the radiator cap tester, apply pressure to the
radiator.
Test pressure:
177 kPa (1.8 kgf/cm2, 26 psi)
SST (c) Submerge the radiator in water.
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 CO–30 2AZ-FE COOLING – RADIATOR

(d) Inspect for leaks.

HINT:
Tank On radiators with resin tanks, there is clearance
between the tank and lock plate where a minute
amount of air will remain, giving the appearance of
Lock an air leak when the radiator is submerged in water.
Plate Therefore, before doing the water leak test, first
swish the radiator around in the water until all air
O-Ring bubbles disappear.
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INSTALLATION
1. INSTALL RADIATOR SUPPORT LOWER
Radiator Support Lower
(a) Install the 2 radiator support lowers to the radiator
assembly.

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2. INSTALL RADIATOR SUPPORT CUSHION

(a) Install the 2 radiator support cushions to the radiator
assembly.

Radiator Support Cushion

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3. INSTALL FAN ASSEMBLY WITH MOTOR

(a) Install the fan assembly with motor to the radiator
CO with the 2 guides at the bottom and 3 snap fits on
the top.

Guide

Snap Fit
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4. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator to the body.

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 2AZ-FE COOLING – RADIATOR CO–31

(b) Install the condenser assembly with the 4 bolts.

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

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(c) Connect the 2 fan motor connectors and the 3

clamps.

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5. INSTALL RADIATOR SUPPORT UPPER

(a) Install the radiator support upper with the 5 bolts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

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(b) Install the hood lock control cable assembly to the

radiator support upper with the clamp. CO

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(c) Install the hood lock assembly to the radiator

support upper with the 3 bolts.
Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
(d) Connect the horn connector.

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 CO–32 2AZ-FE COOLING – RADIATOR

6. CONNECT OIL COOLER OUTLET HOSE (for

Automatic Transaxle)
(a) Connect the oil cooler outlet hose to the radiator
assembly.

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7. CONNECT OIL COOLER INLET HOSE (for Automatic

Transaxle)
(a) Connect the oil cooler inlet hose to the radiator
assembly.

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8. CONNECT RADIATOR HOSE OUTLET

(a) Connect the radiator hose outlet to the radiator
assembly.

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9. CONNECT RADIATOR HOSE INLET

CO (a) Connect the radiator hose inlet to the radiator
assembly.

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10. CONNECT RADIATOR RESERVOIR TANK HOSE

(a) Connect the radiator reservoir tank hose to the
radiator assembly.
11. INSTALL AIR CLEANER INLET ASSEMBLY (See page
EM-120)
12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-419)
13. ADD ENGINE COOLANT (See page CO-5)
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2AZ-FE COOLING – RADIATOR CO–33

14. CHECK FOR ENGINE COOLANT LEAKS (See page

CO-1)
15. INSTALL ENGINE UNDER COVER LH
16. INSTALL ENGINE UNDER COVER RH
17. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
18. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH

CO