TOYOTA CAMRY 1999 Service Repair Manual

CO06D±03
S05322
± COOLING (5S±FE)THERMOSTAT
CO±11
1585 Author: Date:
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, caus-
ing a lowering of cooling efficiency. Do not remove the thermo-
stat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
2. w/ Oil Cooler:
REMOVE OIL FILTER (See page LU±2)
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, and disconnect the water inlet from
the water pump cover.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.

CO06E±03
P13560
P00436
P24125
Valve Lift CO±12
± COOLING (5S±FE)THERMOSTAT
1586 Author: Date:
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature: 80 ± 84°C (176 ± 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

CO0SN±01
P13611
Protrusion
Jiggle
Valve5°5°
S05322
± COOLING (5S±FE)THERMOSTAT
CO±13
1587 Author: Date:
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
3. w/ Oil Cooler:
INSTALL OIL FILTER (See page LU±2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS
6. CHECK ENGINE OIL LEVEL

CO06G±03
CO±14
± COOLING (5S±FE)RADIATOR
1588 Author: Date:
RADIATOR
ON±VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core.)

CO06H±04
Z00570
30° or More
Radiator CapRadiator Cap Tester
B06362
Radiator Cap Tester
± COOLING (5S±FE)RADIATOR
CO±15
1589 Author: Date:
ON±VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
tester at an angle of over 30° above the horizontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester, and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 ± 103 kPa (0.75 ± 1.05 kgf/cm
2, 10.7 ± 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant, and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

CO06I±03
S05951
No.2 Electric
Cooling Fan
Connector
Radiator Assembly
Lower Radiator
Support
Lower Radiator Hose
Upper Radiator Hose
Oil Cooler Hose for A/TUpper Radiator Support
No.1 Electric Cooling Fan Connector
ECT Switch Connector
for Electric Cooling Fan Upper Radiator Support Radiator Reservoir Hose CO±16
± COOLING (5S±FE)RADIATOR
1590 Author: Date:
COMPONENTS

S05948
Lower Radiator Hose
RadiatorNo.2 Electric Cooling Fan
No.1 Electric Cooling
Oil Cooler Hose
for A/T
ECT Switch
Connector for
Electric Cooling
Fan
FanWireClamp
S05240
Upper Tank

O±Ring
Core
Lower Tank
ECT Switch for Electric Cooling Fan
Drain PlugOil Cooler A/T
Pipe
Plate WasherNut

O±Ring
O±Ring

O±Ring Radiator Cap
Nut Plate Washer

Non±reusable part
O±Ring

O±Ring
± COOLING (5S±FE)RADIATOR
CO±17
1591 Author: Date:

CO06J±04
S05955
CO±18
± COOLING (5S±FE)RADIATOR
1592 Author: Date:
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 electric cooling fan connector.
(b) Disconnect the No.2 electric cooling fan connector.
(c) Disconnect the ECT switch connector for the electric cool-
ing fan.
(d) Disconnect the upper radiator hose from the radiator.
(e) Disconnect the lower radiator hose from the water inlet.
(f) Disconnect the radiator reservoir hose from the radiator.
(g) A/T:
Disconnect the 2 oil cooler hoses from the oil cooler pipes.
(h) Remove the 2 bolts and 2 upper radiator supports.
(i) Remove the radiator assembly.
(j) Remove the 2 lower radiator supports.
(k) Remove the lower radiator hose from the radiator.
(l) A/T:
Remove the 2 oil cooler hoses from the radiator.
3. REMOVE NO.1 ELECTRIC COOLING FAN FROM RA-
DIATOR
(a) Disconnect the ECT switch connector for the cooling fan.
(b) Disconnect the ECT switch wire clamp for the cooling fan
from the bracket of the radiator.
(c) Remove the 2 bolts and cooling fan.
4. REMOVE NO.2 ELECTRIC COOLING FAN FROM RA-
DIATOR
Remove the 2 bolts and cooling fan.

CO06K±03
CO1205
Dimension ºBº
Overhaul HandleStopper Bolt SSTPart ºAº
Claw
S04699
Stopper
BoltSSTTank
Lock
Plate
S04703
Ta p
S04705
± COOLING (5S±FE)RADIATOR
CO±19
1593 Author: Date:
DISASSEMBLY
1. REMOVE ECT SWITCH
(a) Remove the ECT switch.
(b) Remove the O±ring.
2. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O±ring.
3. ASSEMBLE SST
SST 09230±01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part ºAº as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº is as shown in the illustration.
Dimension: 0.2 ± 0.3 mm (0.008 ± 0.012 in)
NOTICE:
If this adjustment is not done the claw may be damaged.
4. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
SST 09230±01010
5. REMOVE TANKS AND O±RINGS
Lightly tap the bracket of the radiator (or radiator inlet or outlet)
with a soft±faced hammer, and remove the tank and the O±ring.
6. A/T:
REMOVE OIL COOLER FROM LOWER TANK
(a) Loosen the nut, and remove the cooler pipe.
(b) Remove the 2 nuts and plate washers.
(c) Remove the oil cooler and 2 O±rings.

CO06L±04
S05307
DownwardPipe
18°
CO1267
Lock Plate
CoreLock Plate
CO0317
 Normal
O±RingX Twisted
X Twisted
S04698
Ta pWRONG
CORRECT
Tank
Lock
Plate CO±20
± COOLING (5S±FE)RADIATOR
1594 Author: Date:
REASSEMBLY
1. A/T:
INSTALL OIL COOLER TO LOWER TANK
(a) Install 2 new O±rings to the oil cooler.
(b) Install the oil cooler to the lower tank with the 2 plate
washers and nuts.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
(c) Install the cooler pipe in the direction indicated in the il-
lustration.
Torque: 14.7 N´m (150 kgf´cm, 11 ft´lbf)
2. INSPECT LOCK PLATE FOR DAMAGE
HINT:

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented.
NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
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 pa-
per 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.