2GR-FE COOLING – COOLING SYSTEM CO–1

COOLING SYSTEM
ON-VEHICLE INSPECTION
1. INSPECT 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 118 kPa (1.2 kgf/cm2, 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.
A128110
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) 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 CO
based non-silicate, non-amine, non-nitrite, and non-
borate coolant with long-life hybrid organic acid
technology up to the "FULL" line.
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 any excessive deposits of rust or
scale around the radiator cap and radiator filler hole.
Also, the coolant should be free from oil.
HINT:
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.
 CO–2 2GR-FE COOLING – COOLING SYSTEM

INSPECTION
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
NOTICE:
• If the reservoir cap is contaminated , 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 procedures "A" and "B" below,
keep the tester at an angle of over 30° above the
horizontal.
(a) Using a radiator cap tester, slowly pump the tester
and check that air is being released from the
vacuum valve (Procedure "A").
Pump speed:
1 push every 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not being released from the vacuum valve,
replace the reservoir cap.
A051912 (b) Pump the tester and measure the relief valve
opening pressure (Procedure "B").
Pump speed:
CO 1 push within 1 second
NOTICE:
The pump speed above should be followed for
the first pump only. If will close the vacuum
valve. Once the vacuum valve is closed, the
pump speed can be reduced.
Standard opening pressure:
69.0 to 112.8 kPa (0.70 to 1.15 kgf/cm2, 10.0 to
16.4 psi)
HINT:
Use the tester's maximum reading as the opening
pressure. If the maximum reading is less than the
minimum opening pressure above, replace the
radiator cap.
 2GR-FE COOLING – COOLING FAN SYSTEM CO–3

COOLING FAN SYSTEM

2GR-FE COOLING
ENGINE

PARTS LOCATION

ECT SWITCH

ECM

CO

INSTRUMENT PANEL J/B

FAN ASSEMBLY
- IG1 RELAY
- RDI FAN CTRL ENGINE ROOM R/B AND
ENGINE ROOM J/B - AM1 FUSE
- HTR M-FUSE
- FAN NO.1 RELAY
- ALT H-FUSE

- RDI H-FUSE
A114588E01
 CO–4 2GR-FE COOLING – COOLING FAN SYSTEM

SYSTEM DIAGRAM
The electric cooling fan system controls the fan motors using
the Engine Coolant Temperature (ECT) switch, and turns the
fan relay on and off according to the ECT and the air
conditioner's operating condition.

J/B ECU Gateway ECU ECM

BEAN CAN

Instrument Panel J/B

9 B9
B
IR Temperature sensor
MPX1 14
21
B-W
B45 THW
Engine Room R/B & J/B 1 2

8 2 J/C 6 28
B BR W
IG A41 D46 B45 E2

MICON
4
LG
IH
A14
CO Engine Room R/B & J/B
RDI FAN CTRL

FAN NO. 1 Relay

W
1 1 +B1
3 5 SI
2
LG W-B
1 1 M *(M)
1 2
11 A41
M *(M)
Instrument Panel J/B
M *(S) W-B
8 D46 16 HTR E1
G 1
IF M *(S)

To IG1 Relay

Engine Room R/B & J/B

RDI FAN ALT 1

1 1F W-B

W (*2)
FL MAIN B (*1)
Battery
*1: w/ Smart Entry System F C
*2: w/o Smart Entry System
C A128111E01
 2GR-FE COOLING – COOLING FAN SYSTEM CO–5

ON-VEHICLE INSPECTION
HINT:
The cooling fan may rotate when the ignition switch is turned
from on (IG) to on (ACC), or from on (ACC) to on (IG). This is
normal.
1. CHECK COOLING FAN OPERATION WITH LOW
TEMPERATURE
(a) Turn the ignition switch on (IG).
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT
switches, and check for disconnected connectors or
wire breaks between the cooling fan relay and ECT
switches.
(c) Disconnect the ECT switch No.1 connector.
(d) Connect the terminals on the ECT switch No.1
connector.
(e) Check that the No.1 cooling fan rotates at a high
speed.
If not, check the No. 1 cooling fan relay and No.1
cooling fan.
(f) Reconnect the ECT switch No.1 connector.
(g) Disconnect the ECT switch No.2 connector.
(h) Ground the terminal on the ECT switch No.2 wire
harness side connector.
CO
(i) Check that the No.1 and No.2 cooling fans rotate at
a low speed.
If not, check the No.2 cooling fan relay, No.3 cooling
fan relay and No.2 cooling fan.
(j) Reconnect the ECT switch No.2 connector.
2. CHECK COOLING FUN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan
connector.
(c) Check that the cooling fan rotates smoothly, and
check the reading on the ammeter.
Standard amperage:
8.0 to 12.0 A at 20°C (68°F)
If not, replace the cooling fan.
(d) Reconnect the cooling fan connector.
INSPECTION
5
1 2 1. INSPECT RELAY
(a) Check the resistance of the relay.
3 5

1 2
3

C A128114E01

Resistance
Tester Connection Specified Condition
3-5 10 kΩ or higher
 CO–6 2GR-FE COOLING – COOLING FAN SYSTEM

Tester Connection Specified Condition

Below 1 Ω
3-5
(when battery voltage is applied to terminals 1 and 2)

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

2. INSPECT ECT SWITCH
(a) Check the resistance.
Resistance
Temperature Specified Condition
Above 98°C (208°F) Below 1 Ω
Below 88°C (190°F) 10 kΩ or higher

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

NOTICE:
P001924 When checking the ECT switch in the water, the
terminals should be kept dry. After the check,
dry the switch.

CO
 2GR-FE COOLING – COOLANT CO–7

COOLANT
REPLACEMENT
1. DRAIN ENGINE COOLANT
(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) Drain engine coolant by loosening the radiator drain
cock plug and the engine's cylinder block drain cock
plug.
HINT:
Engine coolant inside the radiator is drained from
the drain hole located on the bottom of the engine
under cover.
(c) Tighten the cylinder block drain cock plugs.

Radiator Cap

CO
Cylinder Block Drain Cock Plug
Cylinder Block Drain Cock Plug

Radiator Drain Cock Plug

A128117E01

Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf)

2. ADD ENGINE COOLANT
(a) Tighten the radiator drain plug (Procedure "A").
(b) Add engine coolant into the radiator until it overflows
(Procedure "B").
Capacity:
8.3 liters (8.8 US qts, 7.3lmp. qts)
HINT:
• Use of improper coolants may damage the
engine cooling system.
 CO–8 2GR-FE COOLING – COOLANT

• Only use "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.
• 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 the coolant.
NOTICE:
Do not use plain water alone.
(c) Pour coolant into the radiator reservoir tank until the
coolant reaches the full line (Procedure "C").
(d) Install the radiator cap (Procedure "D").
(e) Warm up the engine (Procedure "E").
HINT:
As the engine warms up, press the inlet and outlet
radiator hoses several times by hand.
CO (f) Stop the engine and wait until the coolant cools
down to room temperature (Procedure "F").
(g) Remove the radiator cap and check the coolant
level inside the radiator (Procedure "G").
If the coolant level is below the full level, repeat
procedure "C" to "G" until the coolant level. If it is
below the full line, add coolant.
3. CHECK ENGINE COOLANT LEAKS
(a) Fill the radiator with coolant and attach a radiator
cap tester.
(b) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi) and
check leakage.
 2GR-FE COOLING – WATER PUMP CO–9

WATER PUMP
2GR-FE COOLING
ENGINE

COMPONENTS

V-BANK COVER SUB-ASSEMBLY

CO

ENGINE UNDER
COVER RH

A114557E01
 CO–10 2GR-FE COOLING – WATER PUMP

ENGINE MOVING
CONTROL ROD

FAN AND GENERATOR V BELT

ENGINE MOUNTING
CONTROL BRACKET

CO

RADIATOR HOSE OUTLET

A114559E01
2GR-FE COOLING – WATER PUMP CO–11

CO

ENGINE MOUNTING BRACKET FRONT NO.1 LH

A118978E01
 CO–12 2GR-FE COOLING – WATER PUMP

WATER INLET HOUSING

CO

A114566E01
2GR-FE COOLING – WATER PUMP CO–13

VANE PUMP ASSEMBLY

CO

A114561E01
 CO–14 2GR-FE COOLING – WATER PUMP

IDLER PULLEY
CO SUB-ASSEMBLY NO.2

(RR SIDE)

WATER PUMP PULLEY

IDLER PULLEY
SUB-ASSEMBLY NO.2

(FR SIDE)

A114563E01
 2GR-FE COOLING – WATER PUMP CO–15

WATER PUMP ASSEMBLY

CRANKSHAFT PULLEY

CO

A114567E01
 CO–16 2GR-FE COOLING – WATER PUMP

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE ENGINE MOVING CONTROL ROD
6. REMOVE ENGINE MOUNTING CONTROL BRACKET
7. REMOVE ENGINE MOUNTING BRACKET FRONT
NO.1 LH
8. REMOVE FAN AND GENERATOR V BELT
9. SEPARATE RADIATOR HOSE OUTLET
(a) Separate the radiator hose outlet.

CO A128118

10. REMOVE WATER INLET HOUSING

(a) Separate the water hose.
(b) Remove the 2 bolts, nut and water inlet housing.
Water Hose

Water Inlet Housing

A128119E05

(c) Remove the water inlet housing gasket No.1 and

water outlet pipe O-ring.
11. REMOVE CRANKSHAFT PULLEY
SST 09213-70011 (09213-70020), 09330-00021,
09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)

A128120
 2GR-FE COOLING – WATER PUMP CO–17

12. REMOVE WATER PUMP PULLEY

SST
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 4 bolts and water pump pulley.

A128112E03

13. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2

(a) Remove the bolt, idler pulley cover plate No.2 and
idler pulley sub-assembly No.2.

A094887

(b) Remove the bolt, idler pulley cover plate No.2 and
idler pulley sub-assembly No.2.
CO

A128121

(c) Remove the bolt and idler pulley.

NOTICE:
Be careful when loosening the bolt because it is
left-hand threaded.
14. SEPARATE VANE PUMP ASSEMBLY

A128113

15. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump assembly and
water pump gasket.

A094889
 CO–18 2GR-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 noiselessly.
If the bearing moves roughly or noisily, replace the
water pump.

A096655

B INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
B C B B
A A A (a) Install a new water pump gasket and the water
pump assembly with the 16 bolts.
Torque: Bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf)
Bolts B and C
B A
C A
9.1 N*m (93 kgf*cm, 81 in.*lbf)
A A
A A A128115E01
NOTICE:
• Make sure that there is no oil on the threads
of the A bolts.
• Be sure to replace the 2 C bolts with new
CO ones or reuse them after applying adhesive
1344.
Adhesive:
Part No. 08833-00080, THREE BOND 1344 or
equivalent
2. INSTALL VANE PUMP ASSEMBLY
3. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
(a) Install the idler pulley with the bolt.
NOTICE:
Be careful when tightening the bolt because it is
left-hand threaded.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

A128116

(b) Install the idler pulley cover plate No.2 and idler
pulley sub-assembly No.2 with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

A128121
 2GR-FE COOLING – WATER PUMP CO–19

(c) Install the idler pulley cover plate No.2 and idler
pulley sub-assembly No.2 with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

A094887

4. INSTALL WATER PUMP PULLEY

SST
(a) Temporarily install the water pump pulley with the 4
bolts.
(b) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(c) Tighten the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. INSTALL CRANKSHAFT PULLEY
SST 09213-70011 (09213-70020), 09330-00021,
A128112E01
09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
6. INSTALL WATER INLET HOUSING
(a) Install a new water inlet housing No.1 gasket and CO
water outlet pipe O-ring.

A128122

(b) Install the water inlet with the 2 bolts and nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Water Hose NOTICE:
Be careful not to allow the O-ring to get caught
between the parts.
(c) Install the water hose.

Water Inlet Housing

7. INSTALL RADIATOR HOSE OUTLET
(a) Install the radiator hose outlet.
A128123E01 8. INSTALL FAN AND GENERATOR V BELT
9. INSTALL ENGINE MOUNTING BRACKET FRONT
NO.1 LH
10. INSTALL ENGINE MOUNTING CONTROL BRACKET
11. INSTALL ENGINE MOVING CONTROL ROD
12. INSTALL V-BANK COVER SUB-ASSEMBLY
13. ADD ENGINE COOLANT
14. CHECK FOR ENGINE COOLANT LEAKS
15. INSTALL ENGINE UNDER COVER RH
 CO–20 2GR-FE COOLING – WATER PUMP

16. INSTALL FRONT WHEEL RH

CO
 2GR-FE COOLING – THERMOSTAT CO–21

THERMOSTAT
2GR-FE COOLING
ENGINE

COMPONENTS
V-BANK COVER SUB-ASSEMBLY

CO

A114557E02
 CO–22 2GR-FE COOLING – THERMOSTAT

ENGINE MOVING
CONTROL ROD
FAN AND GENERATOR V BELT

ENGINE MOUNTING
CONTROL BRACKET

CO

RADIATOR HOSE OUTLET

A114559E08
 2GR-FE COOLING – THERMOSTAT CO–23

IDLER PULLEY
SUB-ASSEMBLY NO.2 CO
(RR SIDE)

A114563E02
 CO–24 2GR-FE COOLING – THERMOSTAT

CO

ENGINE MOUNTING BRACKET FRONT NO.1 LH

A118978E02
 2GR-FE COOLING – THERMOSTAT CO–25

THERMOSTAT

WATER INLET

CO

A114566E02
 CO–26 2GR-FE COOLING – THERMOSTAT

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER SUB-ASSEMBLY
3. REMOVE ENGINE MOVING CONTROL ROD
4. REMOVE ENGINE MOUNTING CONTROL BRACKET
5. REMOVE ENGINE MOUNTING BRACKET FRONT
NO.1 LH
6. REMOVE FAN AND GENERATOR V BELT
7. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
8. SEPARATE RADIATOR HOSE OUTLET
9. REMOVE WATER INLET
(a) Remove the 2 bolts and water inlet.
10. REMOVE THERMOSTAT
INSPECTION
1. INSPECT THERMOSTAT
(a) Inspect the thermostat.
HINT:
The thermostat is numbered with the valve opening
CO temperature.

P013560

(b) Immerse the thermostat in water and gradually heat

the water.
(c) Check the valve opening temperature.
Valve opening temperature:
80 to 84°C (176 to 183°F)
If the valve opening temperature is not as specified,
replace the thermostat.

P000436

(d) Check the valve lift.

Valve lift:
7.7 mm (0.3031 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 temperature (below 40°C
7.7 mm (104°F)).
If not closed, replace the thermostat.
A091387E02
 2GR-FE COOLING – THERMOSTAT CO–27

10q 10q INSTALLATION

1. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve facing up.
HINT:
The jiggle valve may be set within 10°of either side
of the prescribed position.
2. INSTALL WATER INLET
A128124E01 Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL RADIATOR HOSE OUTLET
4. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
5. INSTALL FAN AND GENERATOR V BELT
6. INSTALL ENGINE MOUNTING BRACKET FRONT
NO.1 LH
7. INSTALL ENGINE MOUNTING CONTROL BRACKET
8. INSTALL ENGINE MOVING CONTROL ROD
9. INSTALL V-BANK COVER SUB-ASSEMBLY
10. ADD ENGINE COOLANT
11. CHECK FOR ENGINE COOLANT LEAKS CO
 CO–28 2GR-FE COOLING – RADIATOR

RADIATOR
2GR-FE COOLING
ENGINE

COMPONENTS
7.0(71, 62 in.*lbf) 7.0(71, 62 in.*lbf) 5.0 (51, 44 in.*lbf)

RADIATOR AIR CLEANER

SUPPORT INLET NO.2
UPPER

HOOD LOCK ASSEMBLY

8.0 (82, 71 in.*lbf)

5.0 (51, 44 in.*lbf)
HOOD LOCK NUT CAP

RADIATOR SUPPORT
CUSHION
7.0 (71, 62 in.*lbf)

5.4 (55, 48 in.*lbf) 8.0 (82, 71 in.*lbf)

RADIATOR SUPPORT
RADIATOR AIR CLEANER INLET NO.1
CUSHION
ASSEMBLY
CO RESERVE TANK
HOSE
FAN MOTOR
CONNECTOR

RADIATOR HOSE INLET

RADIATOR
SUPPORT
LOWER
CONDENSER
RADIATOR SUPPORT
ASSEMBLY
LOWER

5.4 (55, 48 in.*lbf)

OIL COOLER INLET TUBE NO.1

RADIATOR HOSE OUTLET

N*m (kgf*cm, ft.*lbf) : Specified torque OIL COOLER OUTLET TUBE NO.1
A130844E02
 2GR-FE COOLING – RADIATOR CO–29

RADIATOR TANK UPPER

FAN ASSEMBLY WITH MOTOR
RADIATOR CAP
SUB-ASSEMBLY

O-RING

CORE
COOLER PIPE
O-RING 15 (150, 11)
8.3 (85, 73 in.*lbf)

O-RING

OIL COOLER
ASSEMBLY
CO
RADIATOR TANK LOWER O-RING
DRAIN PLUG
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part O-RING

A114590E02

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 Pressures
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
components.
 CO–30 2GR-FE COOLING – RADIATOR

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY
3. REMOVE AIR CLEANER INLET NO.2
4. REMOVE AIR CLEANER INLET NO.1
5. SEPARATE RADIATOR RESERVE TANK HOSE OR
PIPE
(a) Separate radiator reserve tank hose from the
radiator assembly.

A128125

6. SEPARATE RADIATOR HOSE INLET

(a) Separate radiator hose inlet from the radiator
assembly.

CO

A128126

7. SEPARATE RADIATOR HOSE OUTLET

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

A128127

8. SEPARATE OIL COOLER INLET TUBE NO.1

(a) Separate oil cooler inlet tube No.1 from the radiator
assembly.

A128128
2GR-FE COOLING – RADIATOR CO–31

9. SEPARATE OIL COOLER OUTLET TUBE NO.1

(a) Separate oil cooler outlet tube No.1 from the
radiator assembly.

A128129

10. REMOVE RADIATOR SUPPORT UPPER

(a) Remove the hood lock nut cap from the hood lock
assembly.

A128130

(b) Remove the 3 bolts and separate the hood lock

assembly from the radiator support upper.
CO

A128131

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

A128132

11. REMOVE RADIATOR ASSEMBLY

(a) Disconnect the fan motor connector.
(b) Remove the 4 bolts and separate the condenser
assembly from the radiator assembly.

A128133
 CO–32 2GR-FE COOLING – RADIATOR

(c) Remove the radiator assembly from the body.

A128134

12. REMOVE RADIATOR SUPPORT CUSHION

(a) Remove the 2 radiator support cushions from the
radiator assembly.
Radiator Support Cushion
13. REMOVE RADIATOR SUPPORT LOWER
(a) Remove the 2 radiator support lowers from the
radiator assembly.

Radiator Support Lower

A128135E02

14. REMOVE FAN ASSEMBLY WITH MOTOR

(a) Disassemble the 3 snap fits and lift the fan
CO assembly w/motor from the radiator.

Guide
Guide
: Snap Fit A128136E01
 2GR-FE COOLING – RADIATOR CO–33

DISASSEMBLY
1. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O-ring.
2. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
(a) Install the claw to the overhaul handle, inserting it in
Part A the hole in part A as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so
that dimension B is as shown in the illustration.
Dimension B Dimension B:
SST Stopper Bolt 0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTICE:
If the stopper bolt is not adjusted, the claw may
Claw be damaged.
Overhaul Handle
A087082E10

3. REMOVE UNCAULK LOCK PLATE

Tank (a) Using SST to release the caulking, grip the handle
until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)
Lock Plate
SST CO
Stopper Bolt
A128137E01

4. REMOVE RADIATOR TANK UPPER AND TANK

LOWER
(a) Lightly tap the bracket of the radiator (or radiator
hose inlet or outlet) with a soft-faced hammer and
remove the tank.
Tap
(b) Remove the O-ring.

A128138E01

5. REMOVE OIL COOLER ASSEMBLY

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

A128139
 CO–34 2GR-FE COOLING – RADIATOR

Lock plate
INSPECTION
Lock plate 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 lock plate
groove's shape with pliers or a similar object, if
Core
A087087E02
necessary.
• Water leakage will result if the bottom of the lock
plate groove is damaged or dented. Repair or
replace if necessary.
NOTICE:
The radiator can only be recaulked 2 times. After
the 2nd time, the radiator core must be replaced.
REASSEMBLY
(b) (e) 1. INSTALL OIL COOLER ASSEMBLY
Oil Cooler (a) Clean the O-rings contact surface of the lower tank
(f) and oil cooler.
(d) (b) Install 2 new O-rings to the oil cooler.
(d)
(c) Install the oil cooler to the lower tank.
Lower
(b) (d) Install the plate washer and nut.
Tank
CO Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
(e) Install the cooler pipe.
A128140E01
Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
(f) Install the screw.
2. INSTALL RADIATOR TANK UPPER AND TANK
LOWER
(a) After checking that there are no foreign objects in
the lock plate groove, install a new O-ring without
O Normal X Twisted twisting it.
HINT:
O-Ring When cleaning the lock plate groove, lightly rub it
with sand paper without scratching it.
X Twisted
A087088E05

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

CORRECT
(c) Tap the lock plate with a soft-faced hammer so that
there is no gap between the lock plate and the tank.
Tank
3. ASSEMBLE SST
WRONG SST 09230-01010, 09231-14010
Lock
Tap Plate

A128141E01
 2GR-FE COOLING – RADIATOR CO–35

(a) Install the punch assembly to the overhaul handle,

Part A inserting it in the hole in part A as shown in the
illustration.
(b) While gripping the handle, adjust the stopper bolt so
that dimension B is as shown in the illustration.
Dimension B SST Stopper Bolt Dimension B:
8.4 mm (0.331 in.)

Punch Assembly Overhaul Handle

A087090E07

4. CAULK LOCK PLATE

(a) Lightly press SST against the lock plate in the order
5 3 7
shown in the illustration. After repeating this a few
1 2 times, fully caulk the lock plate by gripping the
handle until stopped by the stopper plate.
6 4 8 SST 09230-01010
HINT:
• Do not tap the areas protruding around the pipes,
SST brackets or tank ribs.
Lock Plate • The dotted circles shown in the illustration and
Stopper parts of the oil cooler near the dotted circles
Bolt Tank cannot be tapped with the SST. Use pliers or
similar objects and be careful not to damage the
core plates. CO

A129608E01

(b) Check the lock plate height (H) after completing the
caulking.
Plate height (H):
7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If not within the specified height, adjust the stopper
bolt of the handle and caulk again.
H 5. INSTALL DRAIN PLUG
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.
A128142E01

6. INSPECT FOR WATER LEAKS

(a) Plug the inlet and outlet pipes of the radiator with
SST SST.
SST 09230-01010
(b) Using a radiator cap tester, apply pressure to the
radiator.
Test pressure:
177 kPa (1.8 kgf/cm2, 26 psi)
(c) Submerge the radiator in water.
A128143E02
 CO–36 2GR-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.
A087096E02

INSTALLATION
1. INSTALL FAN MOTOR WITH MOTOR
(a) Install the fan assembly w/ motor to the radiator with
the 2 guides at the bottom and 3 snap fits on the
top.

Guide
Guide
: Snap Fit A129455E01

2. INSTALL RADIATOR SUPPORT LOWER

(a) Install the 2 radiator support lowers to the radiator
CO assembly.
Radiator Support Cushion
3. INSTALL RADIATOR SUPPORT CUSHION
(a) Install the 2 radiator support cushions to the radiator
assembly.

Radiator Support Lower

A129456E01

4. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator to the body.

A129457

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

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(c) Connect the fun motor connector.

A128133
2GR-FE COOLING – RADIATOR CO–37

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)

A128132

(b) Install the hood lock assembly to the radiator

support upper with the 3 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

A128131

(c) Install the hood lock nut cap to the hood lock
assembly.
CO

A128130

6. INSTALL OIL COOLER OUTLET TUBE NO.1

(a) Install oil cooler outlet tube No.1 to the radiator
assembly.

A128129

7. INSTALL OIL COOLER INLET TUBE NO.1

(a) Install oil cooler inlet tube No.1 to the radiator
assembly.

A128128
 CO–38 2GR-FE COOLING – RADIATOR

8. INSTALL RADIATOR HOSE OUTLET

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

A128127

9. INSTALL RADIATOR HOSE INLET

(a) Install radiator hose inlet to the radiator assembly.

A128126

10. INSTALL RADIATOR RESERVE TANK HOSE OR PIPE

(a) Install radiator reserve tank hose to the radiator
CO assembly.
11. INSTALL AIR CLEANER INLET NO.1
12. INSTALL AIR CLEANER INLET NO.2
13. INSTALL BATTERY
14. ADD ENGINE COOLANT
A128125
15. CHECK FOR ENGINE COOLANT LEAKS