Page 1001 of 2389
INSTALLATION OF THERMOSTAT
1. PLACE THERMOSTAT IN WATER PUMP
(a) install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with stud bolt
(A), and insert the thermostat in the water pump.
3. CONNECT WATER TEMPERATURE SENSOR
CONNECTOR
4. INSTALL WATER INLET PIPE
(See steps 3 and 5 on page CO±11)
5. FILL WITH ENGINE COOLANT (See page CO±5)
6. START ENGINE AND CHECK FOR LEAKS2. INSTALL WATER INLET
Install the water inlet with the three nuts.
Torque: 200 kg±cm (14 ft±Ib, 20 N±m)
± COOLING SYSTEMThermostat (2VZ±FE)CO±14
Page 1002 of 2389
INSPECTION OF RADIATOR
1. INSPECT RADIATOR CAP
Using a radiator cap tester, pump the tester and measure the
relief valve opening pressure.
Standard opening pressure:
0.75 ± 1.05 kg/cm
2
(10.7 ± 14.9 psi, 74 ± 103 kPa)
Minimum opening pressure:
0.6 kg/cm
2 (8.5 psi, 59 kPa)
If the opening pressure is less than minimum, replace the
radiator cap.
CLEANING OF RADIATOR
Using water or a steam cleaner, remove any mud and dirt
from the radiator core.
NOTICE: If using a high pressure type cleaner, be careful
not to deform the fins of the radiator core. If the cleaner
nozzle pressure is 30 ± 35 kg/cm
2 (427 ± 498
psi, 2,942 ± 3,432), keep a distance at least 40 ± 50 cm
(15.75 ± 19.69 in.) between the radiator core and cleaner
nozzle.
RADIATOR
COMPONENTS
± COOLING SYSTEMRadiatorCO±15
Page 1003 of 2389

REMOVAL OF RADIATO
1. DRAIN ENGINE COOLANT (See page CO±4 or 5)
2. REMOVE BATTERY
3. REMOVE IGNITION COIL (2VZ±FE), IGNITER AND
BRACKET ASSEMBLY
4. DISCONNECT COOLANT RESERVOIR HOSE
5. DISCONNECT RADIATOR NOSE
6. DISCONNECT COOLING FAN MOTOR
CONNECTOR(S)
7. (A/T)
DISCONNECT OIL COOLER HOSES
8. REMOVE RADIATOR AND ELECTRIC COOLING
FAN(S)
Remove the two bolts, supports and radiator.
9. REMOVE ELECTRIC COOLING FANS FROM RADIATOR
DISASSEMBLY OF RADIATOR
(See page CO±15)
1. REMOVE TANK PLATE
(a) Raise the claws of the tank plates with SST in the
numerical order shown in the figure.
SST 09230±00010
NOTICE: Be careful not to damage the core plate.
2. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 1.2 kg/cm
2 (17.1 psi, 118 kPa), check that
pressure does not drop.
If the pressure drops, check for leaks as the hoses, radiator
or water pump. If no external leaks are found, check the heat-
er core, cylinder block and head.
± COOLING SYSTEMRadiatorCO±16
Page 1004 of 2389
2. CHECK CORE PLATE FOR DAMAGE
HINT:
wIf the sides of the core plate groove are deformed, reassemb-
ly of the tank will be impossible. Therefore, first
correct any deformation with pliers.
wWater leakage will result if the bottom of the core plate groove
is damaged or dented. Therefore, repair or replace if neces-
sary.
ASSEMBLY OF RADIATOR
(See page CO±15)
1. (A/T)
INSTALL OIL COOLER TO LOWER TANK
(a) Install new two 0±rings to the oil cooler.
(b) Install the oil cooler with the two plate washers, spring
washers and nuts. 3. (A/T)
REMOVE OIL COOLER FROM LOWER TANK
Remove the two nuts, spring washers, plate washers, oil
cooler and two 0±rings. 2. REMOVE TANK
(a) Pull the tank upward.
(b) Remove the 0±ring. (b) Pull the tank plates outward.
± COOLING SYSTEMRadiatorCO±17
Page 1005 of 2389
(b) Stake the claws of the tank plates with SST in the nu-
merical order shown in the figure.
SST 09230±00010 4. INSTALL TANK PLATE
Insert new tank plates from both ends in the direction of the
arrows. Firmly set the tank plates in the core plate.3. INSTALL TANK
Install a new O±ring and the tank.
HINT:
wClean the tank and core plate.
5. STAKE CLAWS OF TANK PLATES
(a) Set the punch of SST to ºLOWº.
SST 09230±00010 wTake out any twists.
± COOLING SYSTEMRadiatorCO±18
Page 1006 of 2389
6. CHECK FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230=00010
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 1.8 kg/cm
2 (26 psi, 177 kPa) HINT:
wStake with just enough pressure to leave a mark on the
claw. The staked plate height (H) should be as follows:
Plate height (H):
9.0±9.4 mm (0.354±0.370in.)
NOTICE: If the bottom of the core plate is staked with
the SST on the guide block stopper, it may result in
water leakage.
wThe points shown i n the illustration cannot be staked
with the SST. Use pliers and be careful not to damage
the core plates. wDo not stake the areas protruding around the pipes,
brackets or tank ribs.
± COOLING SYSTEMRadiatorCO±19
Page 1007 of 2389

INSTALLATION OF RADIATOR
1. INSTALL ELECTRIC COOLING FANS TO RADIATOR
2. INSTALL RADIATOR
Place the radiator in position, and install the two supports
with the two bolts.
HINT: After installation, check that the rubber cushion (A)
of the supports are not depressed.
3. (A/T)
CONNECT OIL COOLER HOSES
4. CONNECT COOLING FAN MOTOR CONNECTORS
5. CONNECT RADIATOR HOSES
6. CONNECT COOLANT RESERVOIR HOSE
7. INSTALL IGNITION COIL (2VZ±FE), IGNITER AND
BRACKET ASSEMBLY
8. INSTALL BATTERY
Connect the grand strap.
9. FILL WITH ENGINE COOLANT (See page CO±5)
10. START ENGINE AND CHECK FOR LEAKS
11. (A/T)
CHECK AUTOMATIC TRANSMISSION (A/T) FLUID
LEVEL
NOTICE: Do not overfill.
(d) Check for water leaks.
HINT: On radiators with resin tanks, there is a clearance
between the core plate and tank plate where a minute
amount of air will remain, giving the appearance of an
air leak when the radiator is submerged in water. There-
fore, before performing the water leak test, first switch
the radiator around in the water until all air bubbles dis-
appear.
7. PAINT TANK PLATE
HINT: If the water leak test checks out okay, allow the radia-
tor to completely dry and then paint the tank plate.
± COOLING SYSTEMRadiatorCO±20
Page 1008 of 2389
ON±VEHICLE INSPECTION
Low Temperature (Below 835C (1815F))
1. TURN IGNITION SWITCH ºONº
Check that the fan stops.
If not, check the cooling fan relay and water temperature
switch, and check for a separated connector or severed
wire between the cooling fan relay and water temperature
switch.
2. DISCONNECT WATER TEMPERATURE SWITCH
CONNECTOR
Check that fan rotates.
If not, check the cooling fan relay, fan motor, engine main
relay and fuse, and check for a short circuit between the
cooling fan relay and water temperature switch.
3: CONNECT WATER TEMPERATURE SWITCH
CONNECTOR
ELECTRIC COOLING FAN (3S±FE)
LOCATION OF ELECTRIC COOLING
FAN COMPONENTS
± COOLING SYSTEMElectric Cooling Fan (3S±FE)CO±21