2AZ-FE COOLING – COOLING SYSTEM
CO–1
CO
COOLING SYSTEM
ON-VEHICLE INSPECTION
1. CHECK FOR ENGINE COOLANT LEAKS
NOTICE:
Before performing each inspection, turn the A/C
switch OFF.
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.
(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.
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-

A137456E02
2AZ-FE COOLING – COOLING FAN SYSTEM
CO–3
CO
SYSTEM DIAGRAM
From Battery
From
Ignition Switch
From Battery
RDI FAN
FAN No. 1
FAN No. 3
35
12
FAN No. 2
4
35
1
2
1
2
5231
2
1
ECU IG No. 1
CDS FAN
FANHA24
22
FANLA24
21

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.
2AZ-FE COOLING – COOLANT
CO–5
CO
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

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.
7. CHECK FOR ENGINE COOLANT LEAKS
8. INSTALL ENGINE UNDER COVER RH
9. INSTALL ENGINE UNDER COVER LH
10. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH
11. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
2AZ-FE COOLING – WATER PUMP
CO–7
CO
ENGINE2AZ-FE COOLING

WATER PUMP PULLEY
9.0 (92, 80 in.*lbf)
26 (265, 19)
26 (265, 19)
9.0 (92, 80 in.*lbf)
N*m (kgf*cm, ft.*lbf)
: Specified torque
CLAMP BRACKET
A136759E05
2AZ-FE COOLING – WATER PUMP
CO–9
CO
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 SUB-
ASSEMBLY (See page EM-95)
10. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
(See page EM-96)
11. REMOVE V-RIBBED BELT (See page EM-6)

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.
Clamp Bracket
B012052E03
A129792
Air Hole
Drain Hole
A128603E01
A112198
2AZ-FE COOLING – WATER PUMP
CO–11
CO
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

4. INSTALL V-RIBBED BELT (See page EM-6)
5. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
(See page EM-118)
6. INSTALL ENGINE MOVING CONTROL ROD SUB-
ASSEMBLY (See page EM-119)
7. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See
page EM-119)
8. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL (See page EM-120)
9. ADD ENGINE COOLANT (See page CO-5)
10. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
11. INSTALL ENGINE UNDER COVER LH
12. INSTALL ENGINE UNDER COVER RH
13. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
14. INSTALL FRONT WHEEL OPENING EXTENSION PAD
LH
SST
A098715E02
CO–12
2AZ-FE COOLING – THERMOSTAT
CO
ENGINE2AZ-FE COOLING
THERMOSTAT
COMPONENTS
THERMOSTAT
WATER INLET
9.0 (92, 80 in.*lbf)
GASKET

thermostat.
Standard valve opening temperature:
80 to 84°C (176 to 183°F)
If the valve opening temperature is not as specified,
replace the thermostat.
A112181
P013560E01
P000436E01
CO–14
2AZ-FE COOLING – THERMOSTAT
CO
(d) Check the valve lift.
Standard valve lift:
10 mm (0.39 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the
thermostat.
(e) Check that the valve is fully closed when the
thermostat is at low temperatures (below 77°C
(171°F)).
If it is not fully closed, replace the thermostat.
Valve Lift
A085445E04
2AZ-FE COOLING – THERMOSTAT
CO–15
CO
INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve upward.
HINT:

(b) Measure the current while the motor is turning.
Standard current:
With trailer hitch:
11.8 to 14.8 A at 20°C (68°F)
Without trailer hitch:
7.9 to 10.9 A at 20°C (68°F)
If the result is not as specified, replace the cooling
fan motor.
2. NO. 2 COOLING FAN MOTOR
(a) Check that the motor turns smoothly when the
battery is connected to the fan motor connector.
(b) Measure the current while the motor is turning.
Standard current:
With trailer hitch:
7.9 to 10.9 A at 20°C (68°F)
Without trailer hitch:
7.9 to 10.9 A at 20°C (68°F)
If the result is not as specified, replace the cooling
fan motor No. 2.
Cooling Fan Motor Side Connector:
Negative (-)
Positive (+)
A103699E02
Cooling Fan Motor Side Connector:
Negative (-)
Positive (+)
A103699E02
CO–16
2AZ-FE COOLING – COOLING FAN RELAY
CO

5
5
B060778E01
Tester Connection Specified Condition
3 - 5 10 Ω or higher
3 - 5 Below 1 Ω
(when battery voltage is applied to
terminals 1 and 2)
1
1
2
2
3
3
4
4
5
5
A087121E01
Tester Connection Specified Condition
3 - 4 Below 1 Ω
3 - 5 10 Ω or higher
3 - 4 10 Ω or higher
(when battery voltage is applied to
terminals 1 and 2)
3 - 5 Below 1 Ω
(when battery voltage is applied to
terminals 1 and 2)
3
3

EXTENSION PAD LH
A139342E01
CO–18
2AZ-FE COOLING – RADIATOR
CO
RADIATOR SUPPORT UPPER
HORN CONNECTOR
7.5 (77, 66 in.*lbf)
7.0 (71, 62 in.*lbf)
7.0 (71, 62 in.*lbf)
N*m (kgf*cm, ft.*lbf)
: Specified torque
7.5 (77, 66 in.*lbf)
x2
x2
x2
x9
x2
x4
FRONT BUMPER
ENERGY ABSORBER
FRONT BUMPER ASSEMBLY
HOOD LOCK ASSEMBLY
A134969E02
2AZ-FE COOLING – RADIATOR
CO–19
CO
FAN MOTOR WITH MOTOR
RADIATOR ASSEMBLY
RADIATOR HOSE INLET

DRAIN PLUG
OIL COOLER
ASSEMBLY
RADIATOR TANK LOWER
RADIATOR TANK UPPER
O-RING
RADIATOR CAP SUB-ASSEMBLY
with AUTOMATIC TRANSAXLE
O-RING
O-RING
O-RING
O-RING
15 (150, 11)
8.3 (85, 73 in.*lbf)
N*m (kgf*cm, ft.*lbf)
: Specified torque
Non-reusable part
15 (150, 11)
CORE SUB-
ASSEMBLY
OIL COOLER PIPE
FAN ASSEMBLY
WITH MOTOR
A137802E02
3
1
2
4
A107446E01
2AZ-FE COOLING – RADIATOR

30° or more
A104601E03
Item Specified Condition
Standard valve
(for brand-new cap)
93.3 to 122.7 kPa (0.95 to 1.25 kgf/
cm
2
, 13.5 to 17.8 psi)
Minimum standard valve
(after using cap)
78.5 kPa (0.8 kgf/cm
2
, 11.4 psi)
A073603
Injection Distance Injection Pressure
300 mm (11.81 in.)
2,942 to 4,903 kPa
(30 to 50 kg/cm
2
, 427 to 711 psi)
500 mm (19.69 in.)
4,903 to 7,845 kPa
(50 to 80 kg/cm
2
, 711 to 1,138 psi)
CO–22
2AZ-FE COOLING – RADIATOR
CO
REMOVAL

CO
14. DISCONNECT OIL COOLER INLET HOSE (for
Automatic Transaxle)
(a) Disconnect the oil cooler inlet hose from the radiator
assembly.
15. DISCONNECT OIL COOLER OUTLET HOSE (for
Automatic Transaxle)
(a) Disconnect the oil cooler outlet hose from the
radiator assembly.
16. REMOVE RADIATOR SUPPORT UPPER
(a) Disconnect the horn connector.
(b) Remove the 3 bolts and separate the hood lock
assembly from the radiator support upper.
(c) Remove the clamp and separate the hood lock
control cable from the radiator support upper.
(d) Remove the 5 bolts and radiator support upper.
A133365
A133366
A135235
A135236
A135237