TOYOTA CAMRY 1999 Service Repair Manual

CO1206
Dimension ºBº
Stopper Bolt
Overhaul Handle Punch AssemblyPart ºAº
SST
Z18947
5
SST
Stopper
Tank
Lock 1
64
82 7
3
Plate
Bolt
S05241
(1)
(3)(3)(3)
(1) (2)
(2)
(2)
(2)
(2) (2) (2)
Z18946
± COOLING (5S±FE)RADIATOR
CO±21
1595 Author: Date:
4. ASSEMBLE SST
SST 09230±01010, 09231±14010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part ºAº as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº is as shown in the illustration.
Dimension: 8.4 mm (0.331 in)
5. CAULK LOCK PLATE
(a) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST 09230±01010
HINT:

Do not stake the areas protruding around the pipes,
brackets or tank ribs.

The points shown in the illustration and oil cooler near
here (A/T) cannot be staked with the SST. Use pliers or
similar object and be careful not to damage the core
plates.

S04700
H
S04704
SST
S01713
Tank
Lock
O±RingPlate CO±22
± COOLING (5S±FE)RADIATOR
1596 Author: Date:
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height: 7.40 ± 7.80 mm (0.2913 ± 0.3071 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6. INSTALL ECT SWITCH
(a) Install a new O±ring to the ECT switch.
(b) Install the ECT switch.
7. INSTALL DRAIN PLUG
(a) Install a new O±ring to the drain plug.
(b) Install the drain plug.
8. INSPECT FOR WATER LEAKS
(a) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230±01010
(b) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm
2, 26 psi)
(c) Submerge the radiator in water.
(d) Inspect for leaks.
HINT:
On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
merged in water. Therefore, before doing the water leak test,
first swish the radiator around in the water until all air bubbles
disappear.

CO06M±03
S05955
± COOLING (5S±FE)RADIATOR
CO±23
1597 Author: Date:
INSTALLATION
1. INSTALL NO.1 ELECTRIC COOLING FAN TO RADIA-
TOR
(a) Attach the lower side of the cooling fan to the bracket of
the radiator.
(b) Install the cooling fan with the 2 bolts.
(c) Connect the ECT switch connector for the cooling fan.
(d) Install the ECT switch wire clamp for the cooling fan to the
bracket of the radiator.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)
2. INSTALL NO.2 ELECTRIC COOLING FAN TO RADIA-
TOR
(a) Attach the lower side of the cooling fan to the bracket of
the radiator.
(b) Install the cooling fan with the 2 bolts.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)
3. INSTALL RADIATOR ASSEMBLY
(a) Install the lower radiator hose to the radiator.
(b) A/T:
Install the 2 oil cooler hoses to the radiator.
(c) Install the 2 lower radiator supports to the radiator.
(d) Attach the 2 lower radiator supports on the radiator to the
body brackets.
(e) Install the 2 upper radiator supports with the 2 bolts.
Torque: 12.8 N´m (130 kgf´cm, 9 ft´lbf)
(f) Connect the upper radiator hose to the radiator.
(g) Connect the lower radiator hose to the water inlet.
(h) Connect the radiator reservoir hose to the radiator.
(i) A/T:
Connect the 2 oil cooler hoses to the oil cooler pipes.
(j) Connect the No.1 electric cooling fan connector.
(k) Connect the No.2 electric cooling fan connector.
(l) Connect the ECT switch connector for the electric cooling
fan.
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS

S05959
CO06N±03
S05953
ECT Switch
Connector
Z19282
No.1
No.2Battery
Ammeter (±)
(+) (+)
(±)
Battery Ammeter CO±24
± COOLING (5S±FE)ELECTRIC COOLING FAN
1598 Author: Date:
ELECTRIC COOLING FAN
ON±VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the fan main relay, cooling fan relay, cooling fan,
fuses, and check for short circuit between the cooling fan relay
and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 93°C (199°F))
(a) Start the engine, and raise coolant temperature to above
93°C (199°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT COOLING FANS
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 4.9 ± 8.5 A
(d) Reconnect the cooling fan connector.

CO06O±03
S05950
No.1 Cooling Fan
No.1 Electric Cooling Fan
Upper Radiator HoseNo.1 Electric Cooling Fan Connector
Connector
HolderECT Switch
Connector
ECT Switch
Wire
S05238
Fan
Fan ShroudFan Motor
Connector Holder No.1 Cooling Fan
± COOLING (5S±FE)ELECTRIC COOLING FAN
CO±25
1599 Author: Date:
COMPONENTS

S05949
No.2 Electric Cooling Fan
Connector
No.2 Electric Cooling Fan No.2 Cooling Fan
S05239
FanConnector Holder
Fan ShroudFan MotorFan Motor Cover No.2 Cooling Fan CO±26
± COOLING (5S±FE)ELECTRIC COOLING FAN
1600 Author: Date:

CO06P±03
S05956
S05957
± COOLING (5S±FE)ELECTRIC COOLING FAN
CO±27
1601 Author: Date:
REMOVAL
1. REMOVE NO.1 COOLING FAN
(a) Drain the engine coolant.
(b) Disconnect the upper radiator hose from the radiator.
(c) Remove the No.1 cooling fan.
(1) Disconnect the cooling fan connector.
(2) Disconnect the ECT switch connector.
(3) Remove the 2 bolts, and disconnect the cooling fan
from the radiator.
(4) Disconnect the connector holder and wire for the
ECT switch from the fan shroud, and remove the
cooling fan.
2. REMOVE NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Remove the 2 bolts and cooling fan.

CO06Q±03
S05234
CO±28
± COOLING (5S±FE)ELECTRIC COOLING FAN
1602 Author: Date:
DISASSEMBLY
1. REMOVE FAN
Remove the nut and fan.
2. No.2 Cooling Fan:
REMOVE FAN MOTOR COVER
Remove the 2 screws and motor cover.
3. REMOVE FAN MOTOR
(a) Disconnect the wire and connector holder from the fan
shroud.
(b) Remove the 3 screws and fan motor.

CO06R±04
Z19069
No.1 Cooling Fan
No.2 Cooling Fan
± COOLING (5S±FE)ELECTRIC COOLING FAN
CO±29
1603 Author: Date:
REASSEMBLY
1. INSTALL FAN MOTOR
(a) Install the fan motor with the 3 screws.
(b) Install the wire and connector holder to the fan shroud.
2. No.2 Cooling Fan:
INSTALL FAN MOTOR COVER
Install the motor cover with the 2 screws.
3. INSTALL FAN
Install the fan with the nut.

CO06S±03
S06016Attach
S06017Attach CO±30
± COOLING (5S±FE)ELECTRIC COOLING FAN
1604 Author: Date:
INSTALLATION
1. INSTALL NO.1 COOLING FAN
(a) Install the No.1 cooling fan.
(1) Attach the lower side of the cooling fan to the brack-
et of the radiator.
(2) Install the cooling fan with the 2 bolts.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)
(3) Install the wire and connector holder for the ECT
switch to the fan shroud.
(4) Connect the cooling fan connector.
(5) Connect the ECT switch connector.
(b) Connect the upper radiator hose to the radiator
(c) Fill with engine coolant
(d) Start the engine and check for coolant leaks
2. INSTALL NO.2 COOLING FAN
(a) Attach the lower side of the cooling fan to the bracket of
the radiator.
(b) Install the cooling fan with the 2 bolts.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)
(c) Connect the cooling fan connector.