Toyota Camry 2007-2009 Service Manual - 2GR-FE_Cooling

2GR-FE COOLING – COOLING SYSTEM

COOLING SYSTEM

ON-VEHICLE INSPECTION

1. CHECK FOR ENGINE COOLANT 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. NOTICE: Before performing each inspection, turn the A/C switch OFF.

(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

A133894

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.

CO–2

ENGINE2GR-FE COOLING

2GR-FE COOLING – COOLING FAN SYSTEM

COOLING FAN SYSTEM

PARTS LOCATION

ECM

COOLING FAN ASSEMBLY

-MAIN FAN MOTOR

-SUB FAN MOTOR

-COOLING FAN ECM

INSTRUMENT PANEL JUNCTION BLOCK

-ECU IG NO. 1

ENGINE ROOM RELAY BLOCK

-FAN MAIN FUSE

-COOLING FAN RELAY

A137457E02

2GR-FE COOLING – COOLING FAN SYSTEM

SYSTEM DIAGRAM

CO–3

A54 Cooling Fan ECU

Main Fan Motor

Sub Fan Motor

M+ (M)

M- (M)

M+ (S)

M- (S)

A55 ECM

243

+B1

335

FAN MAIN

ECU IG No. 1

RFC

From Battery

A136998

CO–4

2GR-FE COOLING – COOLING FAN SYSTEM

ON-VEHICLE INSPECTION

1. INSPECT COOLING FAN SYSTEM

(a) Put the vehicle in the following conditions:

(1) The ignition switch is off. (2) The coolant temperature is less than 95°C

(203°F). (3) The battery voltage is between 9 and 14 V. (4) The A/C switch is OFF.

(b) Connect the 400 A probe of the ammeter to

terminals M+ (M) and M+ (S) of the cooling fan motor.

approximately 10 seconds. Check that the fan stops.

(d) Start the engine. Check that the fan stops with the

engine idling. HINT:

• Make sure that the radiator engine coolant

temperature is less than 95°C (203°F).

• Turn the A/C switch OFF.

(e) Check that the fan operates when the A/C switch is

turned ON (MAX COOL and the magnet clutch is operating).

Standard current : Without trailer hitch

Item Specified Condition Cooling fan motor 2 to 8 A Cooling fan motor No. 2 2 to 8 A

Standard current : With trailer hitch

Item Specified Condition Cooling fan motor 2 to 11 A Cooling fan motor No. 2 2 to 11 A

HINT: The coolant temperature is less than 95°C (203°F).

(f) Check that the fan operates when the engine

coolant temperature sensor connector is disconnected.

Standard current : Without trailer hitch

Item Specified Condition Cooling fan motor 2 to 11 A Cooling fan motor No. 2 2 to 11 A

Standard current : With trailer hitch

Item Specified Condition Cooling fan motor 2 to 15 A Cooling fan motor No. 2 2 to 15 A

MAX HI

Fan Speed

2GR-FE COOLING – COOLING FAN SYSTEM

Operating Diagram

A/C OFF

CO–5

(g) After the engine is warmed up, check that the fan

operates as shown in the illustration on the left. HINT:

• The coolant temperature at which the fan starts operating is approximately 95°C (203°F).

• This system can also be checked using the intelligent tester.

• Select the following menu items: Power train / Engine / Data List / Initial Engine Coolant Temp.

95 97 100 102

203 207 212 216

A139339E02

°C

°F

2GR-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 RH

4. REMOVE ENGINE UNDER COVER LH

5. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23)

6. REMOVE COOL AIR INTAKE DUCT SEAL (See page

EM-23)

7. 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 2 cylinder

block drain cock plugs, then drain the coolant.

CO–5

Radiator Cap

Cylinder Block Drain Cock Plug

Radiator Drain Cock Plug

A128117E02

HINT: Collect the coolant in a container and dispose of it according to the regulations in your area.

CO–6

2GR-FE COOLING – COOLANT

8. 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

(b) Slowly fill the radiator with TOYOT A Super Long Life

Coolant (SLLC).

Specified capacity:

9.0 liters (9.5 US qts, 7.9 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.

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.

9. CHECK FOR ENGINE COOLANT LEAKS (See page

CO-1)

10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52)

11. INSTALL ENGINE UNDER COVER RH

12. INSTALL ENGINE UNDER COVER LH

13. INST ALL FRONT WHEEL OPENING EXTENSION P AD RH

14. INST ALL FRONT WHEEL OPENING EXTENSION P AD LH

15. INSTALL COOL AIR INTAKE DUCT SEAL (See page

EM-52)

ENGINE2GR-FE COOLING

WATER PUMP

COMPONENTS

2GR-FE COOLING – WATER PUMP

CO–7

WATER PUMP ASSEMBLY

9.1 (93, 81 in.*lbf)

21 (214, 15)

WATER PUMP PULLEY

43 (438, 32)

NO. 2 IDLER PULLEY SUB-ASSEMBLY

NO. 2 IDLER PULLEY COVER PLATE

×5

×9

GASKET

43 (438, 32)

NO. 2 IDLER PULLEY SUB-ASSEMBLY

NO. 2 IDLER PULLY COVER PLATE

O-RING

43 (438, 32)

V-RIBBED BELT TENSIONER ASSEMBLY

10 (102, 7)

54 (551, 40)

×3

N*m (kgf*cm, ft.*lbf)

×2

: Specified torque

GASKET

WATER INLET HOUSING

NO. 1 ENGINE MOUNTING BRACKET FRONT LH

Non-reusable part

Precoated part

A134976E07

CO–8

FR Side:

2GR-FE COOLING – WATER PUMP

REMOVAL

1. REMOVE ENGINE ASSEMBLY AND TRANSAXLE

HINT: See page EM-23

2. SECURE ENGINE STAND

HINT: See page EM-30

3. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-35)

4. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the 2 bolts, 2 idler pulley cover plates and 2

idler pulley sub-assemblies.

RR Side:

SST

A129645E01

5. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts and V-ribbed belt tensioner

assembly.

A135522

6. REMOVE WATER PUMP PULLEY

(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

2GR-FE COOLING – WATER PUMP

Water Hose

Water Inlet Housing

A133375E01

CO–9

7. REMOVE WATER INLET HOUSING

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

outlet pipe O-ring.

A128120

Drain Hole

8. REMOVE WATER PUMP ASSEMBLY

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

water pump gasket.

A094889

Air Hole

INSPECTION

1. INSPECT WATER PUMP ASSEMBLY

(a) Visually check the drain hole and air hole for coolant

leakage.

(b) Turn the pulley, and check that the water pump

bearing moves smoothly and noiselessly. If the bearing does not move smoothly and noiselessly, replace the water pump.

A096655E06

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY

(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)

A128115E01

NOTICE:

Bolts B and C

9.1 N*m (93 kgf*cm, 81 in.*lbf)

• Make sure that there is no oil on the threads of bolts A.

CO–10

2GR-FE COOLING – WATER PUMP

Water Hose

Water Inlet Housing

• Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344. Adhesive:

T oyot a Genuine Adhesive 1344, Three Bond 1344 or Equivalent

2. INSTALL WATER INLET HOUSING

(a) Install a new water inlet housing No. 1 gasket and

water outlet pipe O-ring.

A128122

(b) Install the water inlet housing with the 2 bolts and

nut.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Be careful not to allow the O-ring to get caught between the parts.

SST

A133375E01

3. INSTALL WATER PUMP PULLEY

(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)

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

A128112E01

4. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner assembly with the

5 bolts.

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

A135522

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Toyota Camry 2007-2009 Service Manual - 2GR-FE_Cooling

Specifications and Main Features

Frequently Asked Questions

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