Toyota Camry 2007-2009 Service Manual - 2AZ-FE_Cooling
2AZ-FE COOLING – COOLING SYSTEM
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.
CO–1
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.
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.
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CO–2
ENGINE2AZ-FE COOLING
2AZ-FE COOLING – COOLING FAN SYSTEM
COOLING FAN SYSTEM
PARTS LOCATION
COOLING FAN MOTOR
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ENGINE ROOM RELAY BLOCK
-COOLING FAN RELAY
-CDS FAN FUSE
-RDI FAN FUSE
INSTRUMENT PANEL JUNCTION BLOCK
-ECU IG FUSE NO. 1
A137456E02
2AZ-FE COOLING – COOLING FAN SYSTEM
SYSTEM DIAGRAM
CO–3
From Battery
From
Ignition Switch
From Battery
RDI FAN
ECU IG No. 1
CDS FAN
A6
A/C Condenser
Fan Motor
FAN No. 3
5231
1
2
FAN No. 1
35
12
FAN No. 2
4
35
1
2
2
1
ECM
22
FANHA24
A7
Radiator
Fan Motor
21
FANLA24
A137000
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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.
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2AZ-FE COOLING – COOLANT
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.
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Radiator Cap
Cylinder Block Drain
Cock Plug
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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 TOYOT A 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.
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7. CHECK FOR ENGINE COOLANT LEAKS
8. INSTALL ENGINE UNDER COVER RH
9. INSTALL ENGINE UNDER COVER LH
10. INST ALL FRONT WHEEL OPENING EXTENSION P AD
LH
11. INST ALL FRONT WHEEL OPENING EXTENSION P AD
RH
ENGINE2AZ-FE COOLING
WATER PUMP
COMPONENTS
52 (531, 38)
2AZ-FE COOLING – WATER PUMP
64 (653, 47)
ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
CO–7
64 (653, 47)
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)
GENERATOR ASSEMBLY
NO. 2 ENGINE MOUNTING BRACKET RH
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FRONT FENDER
APRON SEAL RH
FRONT WHEEL OPENING
EXTENSION PAD LH
N*m (kgf*cm, ft.*lbf)
ENGINE UNDER COVER RH
ENGINE UNDER COVER LH
FRONT WHEEL OPENING
EXTENSION PAD RH
: Specified torque
A136149E02
CO–8
2AZ-FE COOLING – WATER PUMP
CLAMP BRACKET
9.0 (92, 80 in.*lbf)
9.0 (92, 80 in.*lbf)
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26 (265, 19)
WATER PUMP PULLEY
N*m (kgf*cm, ft.*lbf)
26 (265, 19)
WATER PUMP ASSEMBLY
: Specified torque
A136759E05
2AZ-FE COOLING – WATER PUMP
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 SUBASSEMBLY (See page EM-95)
10. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
(See page EM-96)
CO–9
SST
A098715E03
11. REMOVE V-RIBBED BELT (See page EM-6)
12. REMOVE GENERATOR ASSEMBL Y (See page CH-11)
13. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST 09960-10010 (09962-01000, 09963-00700)
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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 conta ct surfaces of
the water pump and cylinder block.
A129792
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Air Hole
Drain Hole
A128603E01
A112198
INSPECTION
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.
(b) Turn the pulley, and then check that the water pump
bearing moves smoothly without making a "click"
sound.
If it does not move smoothly, replace the water
pump assembly.
Seal Diameter
2.2 to 2.5 mm
(0.09 to 0.10 in.)
A-A
AA
0.5 to 1.0 mm
(0.02 to 0.04 in.)
2AZ-FE COOLING – WATER PUMP
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 packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or Equivalent
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.
CO–11
2.5 mm (0.10 in.)
A094495E05
Clamp Bracket
B012052E03
(c) Install the water pump and clamp bracket with the 4
bolts and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
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(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
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