2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
2009 ENGINE Cooling (1GR-FE) - Tundra
COOLING SYSTEM ON-VEHICLE INSPECTION 1. INSPECT FOR COOLANT LEAK 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 the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2 , 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 head.
Fig. 1: Checking Pressure Does Not Drop Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CHECK 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 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-life hybrid organic acid technology to the FULL line. NOTE:
Do not substitute plain water for engine coolant.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 2: Identifying Engine Coolant Level FULL Lines Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. 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. b. Check if there are any excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. c. Install the radiator cap.
COOLANT REPLACEMENT 1. REMOVE NO. 1 ENGINE UNDER COVER (See REMOVAL ) 2. DRAIN ENGINE COOLANT 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. Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 3: Identifying Radiator Drain Cock Plug And Cylinder Block Drain Cock Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the radiator cap. Then drain the coolant. HINT: Collect the coolant in a container and dispose of it according to the regulations in your area. c. Tighten the 2 cylinder block drain cock plugs. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) d. Tighten the radiator drain cock plug by hand. 3. ADD ENGINE COOLANT a. Add engine coolant. Standard capacity: 9.6 liters (10.1 US qts, 8.4 Imp. qts) HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). The thermostat opening timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose. b. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 4: Identifying Radiator Reservoir FULL Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the reservoir cap. d. Press the inlet and outlet radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant. e. Install the radiator cap. f. Start the engine and warm it up until the thermostat opens. HINT: The thermostat opening timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose. g. Maintain the engine speed at 2000 to 2500 rpm. NOTE:
Make sure that the radiator reservoir still has some coolant in it. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature. If there is not enough coolant, the engine may burn out or overheat. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line. Run the engine at 2000 rpm until the coolant level has stabilized.
h. Press the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION:
Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the fan.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
i. Stop the engine, and wait until the engine coolant cools down to ambient temperature. 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. j. Check that the coolant level is between the FULL and LOW lines. If the coolant level is below the LOW line, repeat all of the procedures above. If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines. 4. INSPECT FOR ENGINE COOLANT LEAK (see ON-VEHICLE INSPECTION ) 5. INSTALL NO. 1 ENGINE UNDER COVER (See INSTALLATION )
Fig. 5: Checking Coolant Level Is Between FULL And LOW Lines Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
WATER PUMP COMPONENTS
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 6: Identifying Water Pump Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 7: Identifying Water Pump Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 8: Identifying Water Pump Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 9: Identifying Water Pump Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION 1. REMOVE NO. 1 ENGINE UNDER COVER (See REMOVAL )
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
2. 3. 4. 5. 6. 7.
DRAIN ENGINE COOLANT (see REPLACEMENT ) REMOVE V-BANK COVER (See REMOVAL ) DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET REMOVE FAN SHROUD (see REMOVAL ) INSPECT WATER PUMP ASSEMBLY a. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump assembly.
Fig. 10: Identifying Air Hole And Water Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump assembly. 8. 9. 10. 11. 12. 13. 14.
INSTALL FAN SHROUD (see INSTALLATION ) CONNECT RADIATOR HOSE INLET CONNECT RADIATOR HOSE OUTLET ADD ENGINE COOLANT (see REPLACEMENT ) INSPECT FOR COOLANT LEAK (see ON-VEHICLE INSPECTION ) INSTALL V-BANK COVER (See INSTALLATION ) INSTALL NO. 1 ENGINE UNDER COVER (See INSTALLATION )
REMOVAL 1. 2. 3. 4. 5. 6.
REMOVE NO. 1 ENGINE UNDER COVER (See REMOVAL ) DRAIN ENGINE COOLANT (see REPLACEMENT ) REMOVE V-BANK COVER (See REMOVAL ) DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET REMOVE FAN SHROUD (see REMOVAL )
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
7. REMOVE NO. 2 AIR CLEANER HOSE (See REMOVAL ) 8. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT (See REMOVAL ) 9. REMOVE WATER INLET HOUSING a. Disconnect the 2 oil cooler hoses.
Fig. 11: Identifying Oil Cooler Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 5 water by-pass hoses.
Fig. 12: Identifying Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 5 bolts and water inlet.
Fig. 13: Identifying Bolts And Water Inlet
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the gasket from the water outlet pipe. e. Remove the gasket from the water pump. 10. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY HINT: Use the same procedure for both No. 2 idler pulleys. a. W/ IDLER PULLEY COVER PLATE. (1) Remove the bolt, No. 2 idler pulley cover plate, idler pulley and idler pulley cover plate.
Fig. 14: Identifying Idler Pulleys Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. W/O IDLER PULLEY COVER PLATE. (1) Remove the bolt, No. 2 idler pulley cover plate and idler pulley.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 15: Identifying Idler Pulleys Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See REMOVAL ) 12. REMOVE GENERATOR ASSEMBLY (See REMOVAL ) 13. REMOVE WATER PUMP ASSEMBLY a. Remove the 17 bolts, water pump and gasket.
Fig. 16: Identifying Water Pump Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL WATER PUMP ASSEMBLY a. Install a new gasket and the water pump with the 17 bolts. Torque: for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf) for 12 mm head 23 N*m (235 kgf*cm, 17 ft.*lbf)
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 17: Identifying Water Pump Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL GENERATOR ASSEMBLY (See INSTALLATION ) 3. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See INSTALLATION ) 4. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY HINT: The installation of the No. 2 idler pulleys differs depending on the mark on the No. 2 idler pulleys shown in the illustration.
Fig. 18: Identifying Idler Pulleys Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Use the same procedure for both No. 2 idler pulleys. a. W/ IDLER PULLEY COVER PLATE (PU107013ARMXY3): (1) Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 19: Identifying Idler Pulleys Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If it is necessary to replace the pulley or either plate, replace the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate as a set with new parts. When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3". b. W/O IDLER PULLEY COVER PLATE (PU107013ARMXY1):
(1) Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Fig. 20: Identifying Idler Pulleys Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If it is necessary to replace the pulley or plate, replace both the pulley and plate with a set of new parts that includes a No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate. When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY1". 5. INSTALL WATER INLET HOUSING a. Install a new gasket to the water outlet pipe. b. Install a new gasket to the water pump. c. Apply soapy water to the gasket labeled A shown in the illustration.
Fig. 21: Identifying Water Outlet Pipe Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the water inlet with the 5 bolts.
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
Fig. 22: Identifying Water Inlet Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Connect the 5 water by-pass hoses.
Fig. 23: Identifying Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. 7. 8. 9. 10.
f. Connect the 2 oil cooler hoses. INSTALL FAN SHROUD (see INSTALLATION ) CONNECT RADIATOR HOSE INLET CONNECT RADIATOR HOSE OUTLET INSTALL AIR CLEANER ASSEMBLY WITH ELEMENT (See INSTALLATION ) INSTALL NO. 2 AIR CLEANER HOSE (See INSTALLATION )
2009 Toyota Tundra 2009 ENGINE Cooling (1GR-FE) - Tundra
11. 12. 13. 14.
ADD ENGINE COOLANT (see REPLACEMENT ) INSPECT FOR COOLANT LEAK (see ON-VEHICLE INSPECTION ) INSTALL V-BANK COVER (See INSTALLATION ) INSTALL NO. 1 ENGINE UNDER COVER (See INSTALLATION )
Fig. 24: Identifying Oil Cooler Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
THERMOSTAT COMPONENTS
Thank you very much for your reading. Please Click Here Then Get More Information.