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Documente Profesional
Documente Cultură
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO1
CO4
CO9
CO13
CO20
CO24
CO25
CO1
COOLING
COOLANT
COOLANT
CO06605
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.
If low, check the leakage and add Toyota Long Life Coolant or equivalent up to between the LOW and
FULL lines.
2.
CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap and air release valve 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 water 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.
CO2
COOLING
COOLANT
CO0UB02
REPLACEMENT
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap and air release valve while the engine and radiator are still hot, as fluid and steam can be blown out under
pressure.
1.
DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
(b)
Engine
Drain Plug
Radiator
Drain Plug
(c)
Loosen the radiator and engine drain plugs, and drain the
coolant.
Close the drain plugs.
Torque: 13 Nm (130 kgfcm, 9 ftlbf) for engine
B08216
2.
(a)
(b)
B Mark
LOW Mark
B08221
(c)
Close the air release valve and install the radiator cap securely.
Start the engine.
(d)
HINT:
Warm up the engine with the speed of 2,000 rpm or more and
continue doing it until the thermostat has open and the radiator
reservoir has become hot.
(e) Check the coolant level is above LOW mark.
CO3
COOLING
(f)
3.
4.
COOLANT
After the engine has become cold, check that the water
level becomes below FULL line.
CHECK ENGINE COOLANT FOR LEAK
CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY
CO4
COOLING
WATER PUMP
WATER PUMP
CO06805
COMPONENTS
Timing Belt
* Gasket
9 (90, 78 in.lbf)
Seal Washer
x7
Engine Mounting Bracket
Timing Belt
Tensioner
21 (210, 15)
* Gasket
Oil Pump Insulator
Seal Washer
Crankshaft Pulley
180 (1,800, 130)
Drive Belt
Grommet
Glow Plug
Connector
Glow Plug
B08038
CO5
COOLING
WATER PUMP
Water Pump
z Gasket
Supply Pump
Drive Pulley
Injection Pipe
Plate Washer
*37 (377, 27)
41 (418, 30)
35 (350, 26)
z Gasket
z Gasket
x5
Supply Pump Insulator
41 (420, 30)
20.5 (210, 15)
Intake Manifold
No.2 Engine Cover
34 (345, 25)
B08041
CO6
COOLING
WATER PUMP
CO0VC01
REMOVAL
NOTICE:
S
Befor removing the injection pipes and fuel inlet pipe,
clean them up with a soft brush and compressed air.
S
After removing the fuel inlet pipe and injection pipe,
affix the gum tape on the supply pump, common rail
and the whole injector installatoin area of the cylinder
head cover for preventing dust from coming into
them.
1.
DRAIN ENGINE COOLANT
2.
REMOVE TIMING BELT (See page EM12)
3.
REMOVE NO.1 IDLER AND SUPPLY PUMP DRIVE
PULLEYS (See page EM12)
4.
REMOVE NO.2 ENGINE COVER (See page CO10)
5.
REMOVE SUPPLY PUMP INSULATOR
6.
REMOVE FUEL INLET PIPE (See page FU16)
7.
REMOVE INJECTION PIPES (See page FU6)
8.
REMOVE INTAKE AIR CONNECTOR WITH DIESEL
THROTTLE BODY (See page EM28)
9.
REMOVE INTAKE MANIFOLD (See page EM28)
10.
(a)
(b)
B08018
B08019
CO7
COOLING
WATER PUMP
CO06A05
INSPECTION
Turn
Drain Hole
B08017
1.
INSPECT WATER PUMP
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.
2.
INSPECT TIMING BELT COMPONENTS
(See page EM11)
CO8
COOLING
WATER PUMP
CO0VD01
INSTALLATION
NOTICE:
In case of having the water pump replaced, must replace
the fuel inlet pipe, too.
1.
(a)
(b)
B08019
2.
3.
4.
5.
6.
B08018
7.
8.
9.
10.
11.
CO9
COOLING
THERMOSTAT
THERMOSTAT
CO06C05
COMPONENTS
z Gasket
Thermostat
Water Inlet
z Nonreusable part
B08005
CO10
COOLING
THERMOSTAT
CO0VE01
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, causing a decline in cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.
1.
DRAIN ENGINE COOLANT
(A)
(A)
(B)
2.
(a)
(b)
3.
(a)
A09618
(b)
(c)
B08004
CO11
COOLING
THERMOSTAT
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening temperature.
CO06E05
B08008
(a)
CO0929
(c)
CO12
COOLING
THERMOSTAT
CO0VF01
INSTALLATION
1.
(a)
New Gasket
P10492
(b)
Body
Upward
Cutout
Jiggle
Valve
B08006
CO13
COOLING
RADIATOR
RADIATOR
CO06G05
ONVEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core.)
CO14
COOLING
RADIATOR
CO06H06
ONVEHICLE INSPECTION
1.
REMOVE 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.
30 or More
Radiator Cap
Z00570
2.
INSPECT RADIATOR CAP
NOTICE:
S
If the radiator cap has contaminations, always rinse
it with water.
S
Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
S
When performing steps (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 if 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 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 reduced.
Standard opening pressure:
93.3 122.7 kPa (0.95 1.25 kgf/cm2, 13.5 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm2, 11.4 psi)
HINT:
Use the testers maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radiator cap.
3.
INSPECT COOLING SYSTEM FOR LEAK
(a) Fill the radiator with coolant, and attach a radiator cap tester.
(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 leak. If no external leak is found, check the heater core, cylinder block and head.
4.
REINSTALL RADIATOR CAP
CO15
COOLING
RADIATOR
CO0VG01
COMPONENTS
Upper Tank
z ORing
Core
Drain Plug
z ORing
z ORing
Lower Tank
Water Temperature Switch
for Electric Cooling Fan
z ORing
z Nonreusable part
B08215
CO16
COOLING
RADIATOR
CO0VH01
DISASSEMBLY
1.
(a)
(b)
2.
(a)
(b)
3.
Part A
Dimension B SST
Claw
Stopper Bolt
Overhaul Handle
CO1205
Lock
Plate
Stopper
Bolt
ASSEMBLE SST
SST 0923001010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part A as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so that
dimension B is as shown in the illustration.
Dimension B: 0.2 0.3 mm (0.008 0.012 in)
NOTICE:
If this adjustment is not done the claw may be damaged.
4.
UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
SST 0923001010
Tank
SST
B08209
5.
REMOVE TANKS AND ORINGS
Lightly tap the radiator inlet or outlet (or bracket of the radiator)
with a softfaced hammer, and remove the tank and the Oring.
Tap
B08213
CO17
COOLING
RADIATOR
CO0VI01
Lock Plate
Lock Plate
Core
CO1267
REASSEMBLY
1.
INSPECT LOCK PLATE FOR DAMAGE
HINT:
S
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
S
Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented.
NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
2.
(a)
f Normal X Twisted
HINT:
When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
ORing
X Twisted
CO0317
CORRECT
Tank
WRONG
(b)
(c)
3.
ASSEMBLE SST
SST 0923001010, 0923114010
Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
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.)
Lock
Plate
Tap
B08210
Part A
(a)
Dimension B SST
Punch Assembly
(b)
Stopper Bolt
Overhaul Handle
CO1206
CO18
COOLING
4.
(a)
7
2
1
6
RADIATOR
SST
Tank
Stopper
Bolt
Lock
Plate
B08207
(2)
(2)
(1)
(2)
(2)
(2)
HINT:
S
(2)
(2)
(2)
(2)
(2)
(1)
(2)
(3)
B08214
B08208
(b)
H
B08211
Check the lock plate height (H) after completing the caulking.
Plate height (H): 7.40 7.80 mm (0.2913 0.3071 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
CO19
COOLING
5.
(a)
(b)
6.
(a)
(b)
B08212
RADIATOR
CO20
COOLING
ONVEHICLE INSPECTION
1.
(a)
(b)
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83C (181F))
Turn the ignition switch ON.
Check that the cooling fan stops.
B08217
(c)
(d)
B08234
No.1
Ammeter
3.
(a)
(b)
(c)
Battery
No.2
Ammeter
B03376
B08055
Battery
B08236
(d)
At 20C (68F)
Approx. 13.2 A
No.2
At 20C (68F)
Approx. 9.8 A
CO21
COOLING
COMPONENTS
No.1 Cooling Fan
Fan Motor
CRing
Fan Shroud
Fan
B08230
Fan Motor
Fan Shroud
Fan
B08229
CO22
COOLING
DISASSEMBLY
1.
(a)
(b)
(c)
2.
(a)
(b)
(c)
B08222
B08223
B08224
B08225
CO23
COOLING
REASSEMBLY
1.
(a)
(b)
(c)
2.
(a)
(b)
B08223
B08226
B08225
(c)
B08227
CO24
COOLING
INSPECTION
Water Temperature
Switch Connector
1.
2.
3.
(a)
(b)
(c)
4.
(a)
Ohmmeter
P05962
CO25
COOLING
INSPECTION
1.
(a)
(b)
No.1 Cooling
Fan Relay
B08050
Ohmmeter
No Continuity
1
Ohmmeter
4
3
(c)
2
Continuity
B08044
(d)
Ohmmeter
1
4
3
Continuity
2
Battery
B08045
2.
(a)
(b)
No.2 Cooling
Fan Relay
B08052
Ohmmeter
(c)
Continuity
4
Ohmmeter
Ohmmeter
3
Continuity
No Continuity
S04972
CO26
COOLING
(d)
2 Ohmmeter
5
Battery
Ohmmeter
3
No Continuity
Continuity
S04971
3.
(a)
(b)
No.3 Cooling
Fan Relay
B08052
(c)
Continuity
Ohmmeter
Ohmmeter
No Continuity
S04970
(d)
Ohmmeter
1
5
3
Battery
Continuity
S04969