RADIATOR REMOVAL
Installation is in the reverse order of removal.
1. REMOVE ENGINE UNDER COVER
INSTALLATION HINT: Start the engine, and check for cool-
ant and A/T fluid leaks.
2. REMOVE BATTERY AND BATTERY TRAY
3. DRAIN ENGINE COOLANT
4. 2JZ±GTE:
REMOVE NO.2 AIR TUBE
5. REMOVE NO.2 FAN SHROUD
(a) Remove the 2 clips.
(b) Disconnect the claw of the No.2 fan shroud from the hook of
the No.1 fan shroud, and remove the No.2 fan shroud.
6. REMOVE AIR CLEANER DUCT
7. 2JZ±GTE:
REMOVE NO.5 AIR HOSE
8. REMOVE LH HEADLIGHT BEAM ANGLE GAUGE
Remove the screw and beam angle gauge.
9. DISCONNECT HOSES FROM RADIATOR
Disconnect these hoses from the radiator:
(1) Reservoir inlet hose
(2) Upper radiator hose
(3) Lower radiator hose
(4) A/T:
2 oil cooler hoses
Plug the hose ends.
INSTALLATION HINT: Check the A/T fluid level.
(See item 21 in Maintenance) EG±346
± ENGINECOOLING SYSTEM
RADIATOR ASSEMBLY
1. A/T:
INSTALL OIL COOLER TO LOWER TANK
(a) Clean the O±ring contact surface of the lower tank and oil
cooler.
(b) Install new O±ring (1) to the oil cooler (2).
(c) Install the oil cooler (2) to the lower tank (3).
(d) Install the plate washers (4), and nuts (5).
Torque: 8.3 NVm (85 kgfVcm, 74 in.Vlbf)
(e) Install the inlet pipes (6).
Torque: 15 NVm (150 kgfVcm, 11 ftVlbf)
HINT: Face the inlet pipes in the same direction they were be-
fore disassembly.
2. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT:
wIf the sides of the lock plate groove are deformed,
reassembly of the tank will be impossible.
wTherefore, 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. Therefore,
repair or replace if necessary.
3. INSTALL NEW O±RINGS AND TANKS
(a) After checking that there are no foreign objects in the lock
plate groove, install the new O±ring without twisting it.
HINT: When cleaning the lock plate groove, lightly rub it with
sand paper without scratching it.
(b) Install the tank without damaging the O±ring.
(c) Tap the lock plate with a soft±faced hammer so that there is
no gap between it and the tank. EG±350
± ENGINECOOLING SYSTEM
Engine Coolant Temperature (ECT)
Switch
ECT SWITCH INSPECTION
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE ECT SWITCH
(a) Disconnect the ECT switch connector.
(b) Remove the ECT switch.
(c) Remove the O±ring from the ECT switch.
4. INSPECT ECT SWITCH
(a) Usin g an oh mme te r, ch e ck th a t th e re is no co n tin u ity
between the terminals when the coolant temperature is
above 97°C (207°F).
(b) Using an ohmmeter, check that there is continuity between
the terminals when the coolant temperature is below 88°C
(190°F).
If continuity is not as specified, replace the switch.
5. REINSTALL ECT SWITCH
(a) Install a new O±ring to the ECT switch.
(b) Apply soapy water to the O±ring.
(c) Install the ECT switch.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
(d) Connect the ECT switch connector.
6. REFILL WITH ENGINE COOLANT
7. START ENGINE AND CHECK FOR LEAKS
8. REINSTALL ENGINE UNDER COVER
No.1 Radiator Fan Relay
(ºRADIATOR FAN RELAYº)
RADIATOR FAN RELAY INSPECTION
1. w/ Auto Spoiler:
REMOVE LH HEADLIGHT
2. w/o Auto Spoiler:
REMOVE ENGINE UNDER COVER
3. REMOVE RADIATOR FAN RELAY
4. INSPECT RADIATOR FAN RELAY
A. Inspect relay continuity
(a) Using an ohmmeter, check that there is continuity between
terminals 3 and 4.
(b) Check that there is no continuity between terminals 1 and 2.
If continuity is as specified, replace the relay. EG±356
± ENGINECOOLING SYSTEM
B. Inspect relay operation
(a) Apply battery voltage across terminals 3 and 4.
(b) Using an ohmmeter, check that there is continuity between
terminals 1 and 2.
If operation is not as specified, replace the relay.
5. REINSTALL RADIATOR FAN RELAY
6. w/ Auto Spoiler:
REINSTALL LH HEADLIGHT
7. w/o Auto Spoiler:
REINSTALL ENGINE UNDER COVER
No.2 Radiator Fan Relay
(ºA.B.S. (TRAC) RELAYº)
RADIATOR FAN RELAY INSPECTION
1. w/ Auto Spoiler:
REMOVE LH HEADLIGHT
2. w/o Auto Spoiler:
REMOVE ENGINE UNDER COVER
3. REMOVE RADIATOR FAN RELAY
4. INSPECT RADIATOR FAN RELAY
A. Inspect relay continuity
(a) Using an ohmmeter, check that there is continuity between
terminals 1 and 6.
(b) Check that there is continuity between terminals 3 and 5.
(c) Check that there is no continuity between terminals 2 and 5.
If continuity is not as specified, replace the relay.
B. Inspect relay operation
(a) Apply battery voltage across terminals 1 and 6.
(b) Usin g an oh mme te r, ch e ck th a t th e re is no co n tin u ity
between terminals 3 and 5.
(c) Check that there is continuity between terminals 2 and 5.
If operation is not as specified, replace the relay.
5. REINSTALL RADIATOR FAN RELAY
6. w/ Auto Spoiler:
REINSTALL LH HEADLIGHT
7. w/o Auto Spoiler:
REINSTALL ENGINE UNDER COVER
± ENGINECOOLING SYSTEMEG±357
24
ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[2JZ±GTE]
A 1 A/C Ambient Temp. Sensor E 4 Engine Coolant Temp. Sender (Water Temp. Sender)
A 2 A/C Condenser Fan Motor E 5 Engine Coolant Temp. SW (Water Temp. SW)
A 3 A/C Triple Pressure SW E 6 Engine Hood Courtesy SW
(A/C Dual and Single Pressure SW) E 7 Engine Oil Level Sensor
A 4 A/C Magnetic Clutch and Lock Sensor
A 5 A/T Fluid Temp. Sensor F 1 Front Airbag Sensor LH
A 6 ABS Actuator F 2 Front Airbag Sensor RH
A 7 ABS Actuator F 3 Front Fog Light and Parking Light LH
A 10 ABS Speed Sensor Front LH F 4 Front Fog Light and Parking Light RH
A 11 ABS Speed Sensor Front RH F 5 Front Side Marker Light LH
F 6 Front Side Marker Light RH
B 1 Back±Up Light SW (for M/T) F 7 Front Turn Signal Light LH
B 2 Brake Fluid Level Warning SW F 8 Front Turn Signal Light RH
F 9 Front Wiper Motor
C 1 Camshaft Position Sensor No. 1
C 2 Camshaft Position Sensor No. 2 G 1 Generator (Alternator)
C 3 Crankshaft Position Sensor G 2 Generator (Alternator)
C 4 Cruise Control Actuator
H 1 Headlight Hi LH
D 1 Data Link Connector 1 (Check Connector) H 2 Headlight Hi RH
D 2 Daytime Running Light Relay No. 3 H 3 Headlight Lo LH
D 3 Daytime Running Light Relay No. 3 H 4 Headlight Lo RH
H 5 Heated Oxygen Sensor (Main)
E 1 EGR Gas Temp. Sensor H 8 Horn LH
E 2 Electronically Controlled Transmission Solenoid H 9 Horn RH
E 3 Engine Coolant Temp. Sensor (EFI Water Temp. Sensor)
26
ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[2JZ±GE]
A 1 A/C Ambient Temp. Sensor E 2 Electronically Controlled Transmission Solenoid
A 3 A/C Dual Pressure SW E 3 Engine Coolant Temp. Sensor (EFI Water Temp.
A 4 A/C Magnetic Clutch and Lock Sensor Sensor)
A 5 A/T Fluid Temp. Sensor E 4 Engine Coolant Temp. Sender (Water Temp.
A 6 ABS Actuator Sender)
A 7 ABS Actuator E 6 Engine Hood Courtesy SW
A 8 ABS Relay E 7 Engine Oil Level Sensor
A 9 ABS Relay
A 10 ABS Speed Sensor Front LH F 1 Front Airbag Sensor LH
A 11 ABS Speed Sensor Front RH F 2 Front Airbag Sensor RH
F 3 Front Fog Light and Parking Light LH
B 1 Back-Up Light SW (for M/T) F 4 Front Fog Light and Parking Light RH
B 2 Brake Fluid Level Warning SW F 5 Front Side Marker Light LH
F 6 Front Side Marker Light RH
C 4 Cruise Control Actuator F 7 Front Turn Signal Light LH
F 8 Front Turn Signal Light RH
D 1 Data Link Connector 1 (Check Connector) F 9 Front Wiper Motor
D 4 Distributor
G 1 Generator (Alternator)
E 1 EGR Gas Temp. Sensor G 2 Generator (Alternator)
52
POWER SOURCE (Current Flow Chart)*1: (FOR CANADA)
*2: (FOR USA)
*Page Nos. of
Related Systems
Parts
Code or
Location
CB or FuseT5 70
82
Location
Malfunction Indicator Lamp
(Check Engine Warning Light)
[Telltale Light LH]
* These are the page numbers of the first page on which the related system is shown.
The part indicated is located somewhere in the system, not necessarily on the page indicated here.
7.5A HTR
7.5A IGN
7.5A RAD No. 2
7.5A ST
7.5A TURN
10A ECU±B
10A ECU±IG
10A GAUGE
10A MIR±HTR
10A PANEL
10A TAIL
15A CIG
15A SEAT±HTR
15A STOP
20A WIPER
30A DEFOG
30A DOOR
7.5A ALT±S
7.5A DOME
7.5A DRL
7.5A TRAC
15A FOG
15A HAZ±HORN
15A HEAD (LH) *2
15A HEAD (LH±LWR) *1
15A HEAD (LH±UPR) *1
15A HEAD (RH) *2
15A HEAD (RH±LWR) *1
15A HEAD (RH±UPR) *1
20A RAD No. 1
30A ABS No. 2
30A EFI No. 1
30A EFI No. 2
30A FAN
50A HTR
50A MAIN
60A ABS No. 1
60A POWERT6
T7
T8T9 T11 T12V1
V2V3
V4 V5 V6 V7 164
22068 118102
11 4194 197
70
122
150
181 82
140
174
220
228 60
64
130122 164 206 206 8270
8270
8270 7070
8270
Telltale Light LH
Charge Warning Light
[Telltale Light RH]
Open Door Warning Light
[Telltale Light RH]
Rear Light Warning Light
[Telltale Light RH]
Seat Belt Warning Light
[Telltale Light RH]
SRS Warning Light
[Telltale Light RH]
Telltale Light RH
Theft Deterrent ECU
TRAC Off SW
Traction ECU
Tension Reducer Solenoid LH
Tension Reducer Solenoid RH
VSV (for ACIS)
VSV (for EGR)
VSV (for EVAP)
VSV (for Exhaust Bypass
Valve)
VSV (for Exhaust Gas
Control Valve)
VSV (for Fuel Pressure Up)
VSV (for Intake Air
Control Valve)
[LOCATION](1): J/B No. 1 (See page 20)(2): R/B No. 2 (See page 19)(3): R/B No. 4 (See page 23)
20 22
23
71
2. CONTROL SYSTEM
*SEQUENTIAL MULTIPORT FUEL INJECTION (ELECTRONIC FUEL INJECTION) SYSTEM
THE SEQUENTIAL MULTIPORT FUEL INJECTION (ELECTRONIC FUEL INJECTION) SYSTEM MONITORS THE ENGINE CONDITION
THROUGH THE SIGNALS INPUT FROM EACH SENSOR (INPUT SIGNALS FROM (1) TO (13) ETC.) TO THE ENGINE CONTROL
MODULE (ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU). THE BEST FUEL INJECTION TIMING IS DECIDED
BASED ON THIS DATA AND THE PROGRAM MEMORIZED BY THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY
CONTROLLED TRANSMISSION ECU), AND THE CONTROL SIGNAL IS OUTPUT TO TERMINALS #10, #20, #30, 40, #50 AND #60 OF
THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU) TO OPERATE THE
INJECTOR (INJECT THE FUEL). THE SEQUENTIAL MULTIPORT FUEL INJECTION (ELECTRONIC FUEL INJECTION) SYSTEM
PRODUCES CONTROLS OF FUEL INJECTION OPERATION BY THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY
CONTROLLED TRANSMISSION ECU) IN RESPONSE TO THE DRIVING CONDITIONS.
*ESA (ELECTRONIC SPARK ADVANCE) SYSTEM
THE ESA SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS INPUT TO THE ENGINE CONTROL MODULE
(ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU) FROM EACH SENSOR (INPUT SIGNALS FROM (1), (2), (4) TO
(13) ETC.). THE BEST IGNITION TIMING IS DECIDED ACCORDING TO THIS DATA AND THE MEMORIZED DATA IN THE ENGINE
CONTROL MODULE (ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU) AND THE CONTROL SIGNAL IS OUTPUT
TO TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 AND IGT6 THESE SIGNALS CONTROL THE IGNITER TO PROVIDE THE BEST IGNITION
TIMING FOR THE DRIVING CONDITIONS.
*HEATED OXYGEN SENSOR HEATER CONTROL SYSTEM
THE MAIN HEATED OXYGEN SENSOR, SUB HEATED OXYGEN SENSOR HEATER CONTROL SYSTEM TURNS THE HEATER ON
WHEN THE INTAKE AIR VOLUME IS LOW (TEMP. OF EXHAUST EMISSIONS IS LOW), AND WARMS UP THE OXYGEN SENSOR TO
IMPROVE DETECTION PERFORMANCE OF THE SENSOR. THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY
CONTROLLED TRANSMISSION ECU) EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS FROM (1), (2), (4), (9) TO
(11) ETC.), AND OUTPUTS CURRENT TO TERMINALS HT1, HT2 TO CONTROL THE HEATER.
*IDLE AIR CONTROL (IDLE SPEED CONTROL) SYSTEM
THE IDLE AIR CONTROL (ISC) SYSTEM (STEP MOTOR TYPE) INCREASES THE ENGINE SPEED AND PROVIDES IDLING STABILITY
FOR FAST IDLE±UP WHEN THE ENGINE IS COLD, AND WHEN THE IDLE SPEED HAS DROPPED DUE TO ELECTRICAL LOAD AND SO
ON. THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU) EVALUATE THE
SIGNALS FROM EACH SENSOR (INPUT SIGNALS FROM (1), (4), (5), (8), (9), (11) ETC.), OUTPUTS CURRENT TO TERMINALS ISC1,
ISC2, ISC3 AND ISC4 TO CONTROL THE IDLE AIR CONTROL VALVE (ISC VALVE).
*EGR CONTROL SYSTEM
THE EGR CONTROL SYSTEM DETECTS THE SIGNAL FROM EACH SENSOR (INPUT SIGNALS FROM (1), (4), (9), (10) ETC.), AND
OUTPUTS CURRENT TO TERMINAL EGR TO CONTROL THE EGR VALVE.
*FUEL PUMP CONTROL SYSTEM
THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY CONTROLLED TRANSMISSION ECU) OUTPUTS CURRENT TO
TERMINAL FPC AND CONTROLS THE FUEL PUMP ECU AND FUEL PUMP DRIVE SPEED IN RESPONSE TO THE DRIVING
CONDITIONS.
3. DIAGNOSIS SYSTEM
WITH THE DIAGNOSIS SYSTEM, WHEN THERE IS A MALFUNCTION IN THE ENGINE CONTROL MODULE (ENGINE AND
ELECTRONICALLY CONTROLLED TRANSMISSION ECU) SIGNAL SYSTEM, THE MALFUNCTIONING SYSTEM IS RECORDED IN THE
MEMORY. THE MALFUNCTIONING SYSTEM CAN BE FOUND BY READING THE CODE DISPLAYED BY THE MALFUNCTION INDICATOR
LAMP (CHECK ENGINE WARNING LIGHT).
4. FAIL±SAFE SYSTEM
WHEN A MALFUNCTION HAS OCCURRED IN ANY SYSTEM, IF THERE IS A POSSIBILITY OF ENGINE TROUBLE BEING CAUSED BY
CONTINUED CONTROL BASED ON THE SIGNALS FROM THAT SYSTEM, THE FAIL±SAFE SYSTEM EITHER CONTROLS THE SYSTEM
BY USING DATA (STANDARD VALUES) RECORDED IN THE ENGINE CONTROL MODULE (ENGINE AND ELECTRONICALLY
CONTROLLED TRANSMISSION ECU) MEMORY OR ELSE STOPS THE ENGINE.