radiator assembly TOYOTA CAMRY 1999 Service Repair Manual

AC0LL±02
Z19146
1MZ±FE engine:
No. 1 Engine Coolant Temperature
(ECT) Switch
Compressor
Engine Room Junction Block No. 2

Engine Main Relay
(Marking: ENGINE MAIN)

No. 1 Cooling Fan Relay
(Marking: FAN NO.1)Engine Room Relay Block No. 1

Magnetic Clutch Relay
(Marking: MG CLT)

Heater Main Relay
(Marking: HTR)

No. 2 Cooling Fan Relay
(Marking: FAN NO.2)

No. 3 Cooling Fan Relay
(Marking: FAN NO.3)
5S±FE engine models:
Engine Coolant Temperature
(ECT) Switch Receiver Pressure SwitchCondenser Fan

Fan Motor1MZ±FE engine:
No. 2 Engine Coolant Temperature
(ECT) Switch
Condenser
Blower Unit A/C Unit
A/C Control Assembly

A/C Switch

Blower Speed Control Switch

Mode Switch
Air Outlet Servomotor
Heater Radiator
Thermistor
Blower ResistorBlower Motor 1MZ±FE:
A/C Amplifier Expansion Valve5S±FE engine:
ECM (Built in A/C Amplifier)
Evaporator
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±13
2495 Author: Date:
LOCATION

± AIR CONDITIONINGTROUBLESHOOTING
AC±15
2497 Author: Date:
Cool air comes out only at high engine rpm
1. Refrigerant volume
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Condenser fan
7. Receiver
8. Expansion valve
9. Evaporator
10.Thermistor
11. Refrigerant line
12.Pressure switch
13.*
1 ECM
*2 A/C amplifier
AC±3
AC±16
AC±16
AC±39
AC±52
AC±74
AC±49
AC±59
AC±30
AC±24
AC±21
AC±67
DI±218
AC±88
No engine idle±up when A/C switch ON
1. *1 ECM
*2 A/C amplifier
2. Wire harness
DI±218
AC±88
±
Blinking of A/C indicator
1. *1 ECM
*2 A/C amplifier
2. Thermistor
3. Compressor
DI±218
AC±88
AC±24
AC±39
A/C indicator does not lights up when turn mode switch to DEF.
position
1. A/C Fuse
2. Mode switch
3. A/C switch
4. *
1 ECM
*2 A/C amplifier
5. Wire harness
±
AC±84
AC±84
DI±218
AC±88
±
No warm air comes out
1. Engine coolant volume
2. A/C control assembly
3. Heater radiator±
AC±80
AC±57
No condenser fan operation
1. CDS FAN Fuse
2. Engine main relay
3. Cooling fan relay No. 1
4. Cooling fan relay No. 2
5. Cooling fan relay No. 3
6. Condenser fan motor
7. Pressure switch
8. *
1 Engine coolant temp. switch
*2 No. 1 Engine coolant temp. switch
9. *2No. 2 Engine coolant temp. switch
10.Wire harness
±
±
AC±72
AC±72
AC±72
AC±74
AC±67
AC±92
AC±92
AC±92
±
*1: 5S±FE Engine Models
*
2: 1MZ±FE Engine Models

AC21X±01
N20287
N20283
N20243
x13Water Seal
Plate
EvaporatorInsurator
N20293
± AIR CONDITIONINGAIR CONDITIONING UNIT
AC±29
2511 Author: Date:
DISASSEMBLY
1. REMOVE AIR OUTLET SERVOMOTOR
(a) Release the claw and pull out the plate.
(b) Remove the 3 screws and servomotor.
2. REMOVE HEATER RADIATOR
(a) Remove the 3 screws and 3 plates.
(b) Remove the 2 clips and heater radiator pipes.
(c) Pull out the heater radiator.
3. REMOVE THESE FOOT AIR DUCT LH
4. REMOVE EXPANSION VALVE
(a) Remove piping clamp.
(b) Remove the packings.
(c) Using a hexagon wrench (5.0 mm, 0.20 in.), remove the
2 bolts and separate the expansion valve and evaporator.
5. REMOVE EVAPORATOR
(a) Remove the grommet from the evaporator.
(b) Using a knife, cut off each packings.
HINT:
Do not reuse the packing.
(c) Remove the 13 screws and separate the heater cases,
then remove the evaporator and water seal.
(d) Release the 4 claws and remove the plate from the evap-
orator.
6. PEEL OFF THE WATER SEAL FROM HEATER UNIT
7. REMOVE THERMISTOR
Pull out the thermistor with the holders.

BO0KV±01
H01708
Turn Signal Light Assembly
Upper Reinforcement
Sub±AssemblyTurn Signal Light Assembly
Fender Liner Front Bumper
Reinforcement
Energy Absorber
Mounting Plate
Front Bumper
Energy Absorber
Engine Under Cover Bumper Cover Emblem,
Radiator GrillFender Liner
N´m (kgf´cm, ft´lbf) : Specified torque
5.5 (55, 49 in.´lbf)34 (350, 25)
Clip
34 (350, 25)
No.2
Reinforcement
Clip BO±4
± BODYFRONT BUMPER
2352 Author: Date:
FRONT BUMPER
COMPONENTS

S05939
No.2 Timing Belt
Cover
No.1 Timing Belt
Cover
Crankshaft
Pulley
No.2 Idler Pulley
Generator Drive Belt
Adjusting Bar
Wire Clamp
Crankshaft Position Sensor
Connector* Gasket
No.1 Idler Pulley
Tension Spring

O±Ring
Water PumpWater PumpTiming Belt
Timing Belt Guide
Lower
Radiator
Hose Water Pump and
Water Pump Cover
Assembly High±Tension Cord Generator Wire

Gasket Wire Clamp
Wire Clamp
Wire ClampWire Clamp Wire
Clamp
* GasketGenerator Connector
Generator
Spark Plug

O±Ring

Gasket
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
108 (1,100, 80)18 (180,13)
42 (425,31)
42 (425,31)
* Replace only if damagedCover CO±4
± COOLING (5S±FE)WATER PUMP
1578 Author: Date:

CO069±04
S05599
S05924
S05963
1
2
3
± COOLING (5S±FE)WATER PUMP
CO±5
1579 Author: Date:
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE TIMING BELT (See page EM±17)
3. DISCONNECT LOWER RADIATOR HOSE FROM WA-
TER OUTLET
4. REMOVE TIMING BELT TENSION SPRING
Loosen the No.1 idler pulley bolt, and remove the tension
spring.
5. REMOVE NO.2 IDLER PULLEY
Remove the bolt and idler pulley.
6. w/ Oil Cooler:
REMOVE A/C COMPRESSOR (See page EM±69)
7. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the engine wire clamp from the adjusting bar.
(b) Disconnect the crankshaft position sensor connector
from the bracket on the adjusting bar.
(c) Remove the bolt and adjusting bar.
8. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.

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

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.