CO-1

COOLING (1GR-FE) - COOLANT

COOLANT
CO1D4-01

INSPECTION
HINT:
Check the coolant level when the engine is cold.
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines at normal temperature
(20°C(68°F)).
If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology
up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
(c) Reinstall the radiator cap.

Author
: Date
: 3670

CO-2
COOLING (1GR-FE) - COOLANT
CO1D5-01

REPLACEMENT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot as fluid
and steam can be blown out under pressure.
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.

Radiator Cap Drain Plug

(b) Remove the 3 drain plugs on the engine and radiator, and
drain the coolant.
(c) Close the 3 drain plugs.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) for engine
3. REFILL WITH ENGINE COOLANT
(a) Slowly fill the system with coolant.
Capacity: 11.6 liters (12.3 US qts, 10.2 Imp. qts)
NOTICE:
Radiator drain Plug
A23113 Do not use plain water alone.
HINT:

Use of improper coolants may damage the engine cooling
system.

Use ”Toyota Super Long Life Coolant” or similar high qual-
ity ethylene glycol based non-silicate, non-amine, non-
nitrite, and non-borate coolant with long-life hybrid or-
ganic acid technology.

New Toyota vehicles are filled with Toyota Super Long
Life Coolant (color is pink, premixed ethylene glycol con-
centration is approximately 50 % and freezing tempera-
ture is -35°C (-31°F)). When replacing the coolant, Toyo-
ta 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.
(b) Install the radiator cap.
(c) Bleed the cooling system.
(1) Start the engine, and open the heater water valve.
(2) Maintain the engine speed at 2,000 - 2,500 rpm,
and warm up the engine.
(d) Stop the engine, and wait until the engine coolant cools
down.
(e) Refill coolant into the reservoir until it is ”FULL”.
4. CHECK FOR ENGINE COOLANT LEAKS
5. CHECK ENGINE COOLANT SPECIFIC GRAVITY COR-
RECTLY
6. REINSTALL ENGINE UNDER COVER

Author
: Date
: 3671

CO-16
COOLING (1GR-FE) - RADIATOR
CO1DF-01

COMPONENTS
5.0 (50, 44 in.·lbf)
Radiator Assembly
No.2 Fan Shroud

12 (120, 9)

No.1 Fan Shroud

Oil Cooler Pipe for

AutomaticTransmission

V-Belt Fan w/ Fluid Coupling Fan Pulley

21 (214, 15)

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

B17658

Author
: Date
: 3685

CO-18
COOLING (1GR-FE) - RADIATOR
CO1DH-01

INSTALLATION
1. INSTALL NO.1 FAN SHROUD
Install the No.1 fan shroud with the 4 bolts.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

2. INSTALL RADIATOR ASSEMBLY

(a) Set the radiator bracket hooks to the radiator support
holes.
(b) Install the 4 bolts.
Torque: 12 N·m (120 N·m, 9 ft·lbf)
3. INSTALL NO.2 FAN SHROUD
Install the No.2 fan shroud with the 2 clips.
4. CONNECT A/T OIL COOLER HOSES TO RADIATOR
B07220 5. CONNECT UPPER RADIATOR HOSE TO RADIATOR
6. CONNECT LOWER RADIATOR HOSE TO RADIATOR
7. CONNECT RADIATOR RESERVOIR HOSE TO RADIA-
TOR
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR ENGINE COOLANT
LEAKS
10. RECHECK ENGINE COOLANT LEVEL
11. INSTALL ENGINE UNDER COVER

Author
: Date
: 3687

CO-14
COOLING (1GR-FE) - RADIATOR

RADIATOR CO1DD-01

ON-VEHICLE CLEANING
INSPECT FINS FOR BLOCKAGE
If fins are clogged, wash them with water or a steam cleaner and
dry with compressed air.
NOTICE:

If the distance between the steam cleaner and the
B14807
core is too close, there is a possibility of damaging
the fin, so keep the following injection distance.
Injection Pressure Injection Distance
2,942 to 4,903 kpa
300 mm (11.811 in)
(30 to 50 kg/cm2, 427 to711 psi)

4,903 to 7,845 kpa

500 mm (19.685 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 compo-
nents.

Author
: Date
: 3683

 CO-15
COOLING (1GR-FE) - RADIATOR
CO1DE-01

ON-VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.

2. INSPECT RADIATOR CAP

Radiator Cap Tester NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
30° or More
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
Radiator Cap tester at an angle of over 30° above the horizontal.
CO1242 (a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the radiator cap tester, and measure the relief valve
opening pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Opening pressure:
Standard 93 to 123 kPa (0.95 to 1.25 kgf/cm2,13.5 to 17.8 psi)
Minimum 78 kPa (0.8 kgf/cm2, 11.4 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.

3. INSPECT COOLING SYSTEM FOR LEAKS

Radiator Cap Tester (a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it 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,
B07240 cylinder block and head.
4. REINSTALL RADIATOR CAP

Author
: Date
: 3684

 CO-17
COOLING (1GR-FE) - RADIATOR
CO1DG-01

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT RADIATOR RESERVOIR HOSE FROM
RADIATOR
4. DISCONNECT UPPER RADIATOR HOSE FROM RA-
DIATOR
5. DISCONNECT LOWER RADIATOR HOSE FROM RA-
DIATOR
6. DISCONNECT A/T OIL COOLER HOSES FROM RA-
DIATOR
7. REMOVE NO.2 FAN SHROUD
Remove the 2 clips and No.2 fan shroud.

8. REMOVE RADIATOR ASSEMBLY

Remove the 4 bolts and radiator assembly.
9. REMOVE NO.1 FAN SHROUD
Remove the 4 bolts and No.1 fan shroud.

B07219

Author
: Date
: 3686

CO-12
COOLING (1GR-FE) - THERMOSTAT
CO1DB-01

INSPECTION
INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the thermostat.

A23110

(a) Immerse the thermostat in the water, then heat the water
gradually.
(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.

A23111

(c) Check the valve lift.

Valve lift: 8 mm (0.31 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 temperature (below 40
C (104
F)).
If not fully closed, replace the thermostat.

Valve Lift

A23112

Author
: Date
: 3681

 CO-13
COOLING (1GR-FE) - THERMOSTAT
CO1DC-01

INSTALLATION
1. INSTALL WATER INLET W/THERMOSTAT
(a) Install a new gasket to the water inlet w/ thermostat.
(b) Install the water inlet w/ thermostat with the 3 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
2. CONNECT RADIATOR OUTLET, NO.2 HOSE CLAMP
OR CLIP
3. ADD ENGINE COOLANT (See page CO-2 )
A23122
4. CHECK FOR ENGINE COOLANT LEAKS
5. INSTALL V-BANK COVER
Install the V-bank cover with the 2 nuts.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

Author
: Date
: 3682

 CO-1 1
COOLING (1GR-FE) - THERMOSTAT

THERMOSTAT CO1DA-01

REMOVAL
HINT:
If the thermostat was not installed, cooling efficiency would be
harmed. If the engine should tend to overheat, do not remove
the thermostat.
1. DRAIN ENGINE COOLANT (See page CO-2 )
2. REMOVE V-BANK COVER
3. DISCONNECT RADIATOR OUTLET, NO.2 HOSE
CLAMP OR CLIP

4. REMOVE WATER INLET W/THERMOSTAT

(a) Remove the 3 nuts, water inlet w/ thermostat and gasket.

A23122

Author
: Date
: 3680

 CO-3
COOLING (1GR-FE) - WATER PUMP

WATER PUMP
CO1D6-01

COMPONENTS

9.8 (100, 87 in.·lbf)

V-Bank Cover

Air Cleaner Hose

Vacuum Hose

Mass Air Flow

Meter Connector

Ventilation Hose Air Cleaner Case

Battery Clamp

Battery

Engine Under Cover

Battery Tray

x5

N·m (kgf·cm, ft·lbf) : Specified torque B17654

Author
: Date
: 3672

CO-4
COOLING (1GR-FE) - WATER PUMP

No.1 Fan Shroud 5.0 (50, 44 in.·lbf)

Radiator Assembly
No.1 Fan Shroud

12 (120, 9)

Oil Cooler Pipe for

AutomaticTransmission

V-Belt Fan w/ Fluid Coupling Fan Pulley

21 (214, 15)

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

A23385

Author
: Date
: 3673

 CO-5
COOLING (1GR-FE) - WATER PUMP

Water By-pass Hose No.2

Water By-pass Hose No.3

O-ring
Water By-pass
Hose No.1

O-ring

Water Inlet

9.0 (92, 80 in.·lbf)

Oil Cooler Hose

Gasket
Water Pump

Idler Pulley No.2

V-Ribbed Belt Tensioner

Washer

54 (551, 40)

Idler Pulley No.1

36 (367, 27)

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

Non-reusable part B17653

Author
: Date
: 3674

CO-8
COOLING (1GR-FE) - WATER PUMP
CO1D8-01

Air Hole INSPECTION

Water 1. INSPECT WATER PUMP
Hole
(a) Visually check the air hole and water hole for coolant leak-
age.
If leakage is found, replace the water pump and timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.
A23108

2. INSPECT FLUID COUPLING

(a) Check that the fluid coupling is not damaged and that no
silicon oil leaks.
If necessary, replace the fluid coupling.

A23109

Author
: Date
: 3677

 CO-9
COOLING (1GR-FE) - WATER PUMP
CO1D9-01

INSTALLATION
1. INSTALL WATER PUMP
(a) Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for 12 mm (0.47 in.) head
2. INSTALL V-RIBBED BELT TENSIONER ASSY
(See page EM-44 )
A22973
3. INSTALL COOLER COMPRESSOR
(See page EM-108 )
4. INSTALL GENERATOR (See page CH-15 )
5. INSTALL IDLER PULLEY
(a) Install the 2 idler pulleys with the 2 bolts.
Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf)

6. INSTALL WATER INLET

(a) Install a new O-ring to the water outlet pipe.
(b) Install a new gasket to the water pump.
(c) Apply soapy water to the O-ring.

A23120

(d) Install the water inlet with the 5 bolts.

Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(e) Connect the 5 water by-pass hoses.
(f) Connect the 2 radiator hoses.
(g) Connect the 2 oil cooler hoses (w/ oil cooler).
7. INSTALL AIR CLEANER
8. CONNECT VENTILATION HOSE NO.2

A23121

9. INSTALL FAN W/ FLUID COUPLING

(a) Put the fan pulley to the water pump.
(b) Put the fan w/ fluid coupling and fan shroud together.
(c) Temporarily install the 4 fluid coupling nuts.
(d) Tighten the 4 fan shroud bolts.
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
(e) Connect the reserve tank hose.
(f) Fasten the 2 oil cooler hoses with the hose clamp.
A23114

Author
: Date
: 3678

CO-10
COOLING (1GR-FE) - WATER PUMP

10. INSTALL FAN AND GENERATOR V BELT

(See page EM-89 )
11. FULLY TIGHTEN FAN W/ FLUID COUPLING
(a) Tighten the 4 fluid coupling bolts.
Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf)
12. ADD ENGINE COOLANT (See page CO-2 )
13. CHECK FOR ENGINE COOLANT LEAKS
14. INSTALL ENGINE UNDER COVER
(a) Install the engine under cover with the 4 bolts.
Torque: 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf)
15. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
16. RECHECK ENGINE COOLANT LEVEL
17. FILL WITH ENGINE COOLANT
18. START ENGINE AND CHECK FOR ENGINE COOLANT
LEAKS
19. RECHECK ENGINE COOLANT LEVEL

Author
: Date
: 3679

CO-6
COOLING (1GR-FE) - WATER PUMP
CO1D7-01

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER

4. LOOSEN FAN W/ FLUID COUPLING

(a) Loosen the 4 fluid coupling bolts.
5. REMOVE FAN AND GENERATOR V BELT
(See page EM-62 )
6. REMOVE FAN W/ FLUID COUPLING
(a) Disconnect the radiator reserve tank hose.
(b) Remove the 4 fan shroud bolts.
(c) Remove the 4 fluid coupling nuts, and then remove the
A23114 fan w/ fluid coupling and fan shroud together.
(d) Remove the fan pulley.
7. DISCONNECT VENTILATION HOSE NO.2
8. REMOVE AIR CLEANER

9. REMOVE WATER INLET

(a) Disconnect the 2 oil cooler hoses (w/ oil cooler).

A23116

(b) Disconnect the 2 radiator hoses.

A23117

Author
: Date
: 3675

 CO-7
COOLING (1GR-FE) - WATER PUMP

(c) Disconnect the 5 water by-pass hoses.

A23118

(d) Remove the 5 bolts and water inlet.

(e) Remove the O-ring from the water outlet pipe.
(f) Remove the gasket from the water pump.

A23119

10. REMOVE IDLER PULLEY NO.2

(a) Remove the 2 bolts and 2 idler pulleys.
11. REMOVE GENERATOR (See page CH-7 )
12. SEPARATE COOLER COMPRESSOR
(See page EM-105 )
13. REMOVE V-RIBBED BELT TENSIONER
(Seepage EM-32 )

A22878

14. REMOVE WATER PUMP

(a) Remove the 17 bolts, water pump and gasket.

A22973

Author
: Date
: 3676