service repair manual

1. Last Modified: 11-29-2007 1.6 A
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM0000017DS00YX
Title: 3UR-FE COOLING: COOLANT: REPLACEMENT (2008 Sequoia)
REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER
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.
HINT:
Collect the coolant in a container and dispose of it according to the regulations in your area.
(a) Loosen the radiator drain cock plug.
(b) Remove the radiator cap. Then drain the coolant from the radiator.
(c) Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.
(d) Tighten the 2 cylinder block drain cock plugs.
Torque: 13 N·m (133 kgf·cm, 10 ft·lbf)
(e) Tighten the radiator drain cock plug by hand.
3. ADD ENGINE COOLANT
(a) Add engine coolant.
Standard Capacity
ITEM SPECIFIED CONDITION
w/ Trailer Towing System 13.0 liters (13.7 US qts., 11.4 Imp. qts.)
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2. ITEM SPECIFIED CONDITION
w/o Trailer Towing System 12.1 liters (12.8 US qts., 10.6 Imp. qts.)
NOTICE:
Do not substitute plain water for engine coolant.
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).
• Please contact any authorized Toyota dealer or qualified repair shop for further details.
(b) Slowly pour coolant into the radiator reservoir until
it reaches the FULL line.
(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 radiator inlet 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.
NOTICE:
• 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.
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3. (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 COOLANT LEAK
5. INSTALL NO. 1 ENGINE UNDER COVER
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4. Last Modified: 11-29-2007 1.6 A
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM0000017DS00XX
Title: 2UZ-FE COOLING: COOLANT: REPLACEMENT (2008 Sequoia)
REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER
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.
(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 (130 kgf·cm, 10 ft·lbf)
(d) Tighten the radiator drain cock plug by hand.
3. ADD ENGINE COOLANT
(a) Add engine coolant.
Standard capacity:
9.7 liters (10.3 US qts, 8.5 Imp. qts)
HINT:
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5. • 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.
(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 and warm up the engine until the cooling fan
operates.
NOTICE:
• 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.
(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.
(i) Stop the engine, and wait until the engine coolant cools down.
(j) If the coolant level is below the LOW line, repeat all of
the procedures above.
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6. 4. INSPECT FOR COOLANT LEAK
5. INSTALL NO. 1 ENGINE UNDER COVER
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7. Last Modified: 11-29-2007 1.6 G
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM000000V1Q044X
Title: 3UR-FE COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (2008 Sequoia)
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/cm
2
, 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.
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.
NOTICE:
Do not substitute plain water for engine coolant.
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.
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8. If excessively dirty, clean the coolant passage and replace the coolant.
(c) Install the radiator cap.
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9. Last Modified: 11-29-2007 1.6 G
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM000000V1Q049X
Title: 2UZ-FE COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (2008 Sequoia)
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.
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.
NOTICE:
Do not substitute plain water for engine coolant.
3. INSPECT ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
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10. 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.
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11. Last Modified: 11-29-2007 1.6 G
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM000000XYW03EX
Title: 3UR-FE COOLING: RADIATOR: ON-VEHICLE INSPECTION (2008 Sequoia)
ON-VEHICLE INSPECTION
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and
radiator are still hot, as fluid and steam can be blown out under pressure.
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean it by using
water and finger scouring.
(2) Check that rubber packing 1, 2 and 3 are not deformed, cracked or swollen.
(3) Check that rubber packing 3 and 4 are not stuck together.
(4) Apply engine coolant to rubber packing 2 and 3.
(5) Prepare a radiator cap tester, and tilt it more
than 30°.
(6) Pump the cap tester several times, and check the maximum pressure*.
Pumping speed:
1 pump per second
HINT:
*: Even if the cap cannot maintain the maximum pressure, it is not a defect.
Standard Judgment Criterion:
ITEM SPECIFIED CONDITION
Standard value 93 to 123 kPa (1.0 to 1.3 kgf/cm2
, 13.5 to 17.8 psi)
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13. ITEM SPECIFIED CONDITION
(for brand-new cap)
Minimum standard value
(after using cap)
78.5 kPa (0.8 kgf/cm
2
, 11.4 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
2. INSPECT FINS FOR BLOCKAGE
(a) Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the
hose connections.
If the fins are blocked, wash them with water or a steam cleaner.
NOTICE:
• If the distance between the steam cleaner and core is too close, the fins may be damaged.
• Keep the following injection distance.
Standard Injection Distance:
INJECTION CONDITION INJECTION PRESSURE
300 mm (11.8 in.) 2942 to 4903 kPa (30.0 to 50.0 kgf/cm
2
, 427 to 711 psi)
500 mm (19.7 in.) 4903 to 7845 kPa (50.0 to 80.0 kgf/cm
2
, 711 to 1138 psi)
• If the fins are bent, straighten them with a screwdriver or pliers.
• Never apply water directly onto the electric components.
(b) Dry the fins with compressed air.
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14. Last Modified: 11-29-2007 1.6 A
Service Category: Engine/Hybrid System Section: Cooling
Model Year: 2008 Model: Sequoia Doc ID: RM000002BGG00GX
Title: 2UZ-FE COOLING: RADIATOR: INSTALLATION (2008 Sequoia)
INSTALLATION
1. INSTALL RADIATOR DRAIN COCK PLUG
(a) Install the radiator drain cock plug to the radiator assembly.
2. INSTALL OUTLET RADIATOR HOSE
(a) Install the outlet radiator hose to the radiator assembly.
3. INSTALL RADIATOR ASSEMBLY
(a) Set the radiator bracket hooks to the radiator support holes.
(b) Install the radiator with the 4 bolts.
Torque: 18 N·m (184 kgf·cm, 13 ft·lbf)
4. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL
(a) Install the No. 1 radiator to support seal with the 3 clips.
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15. 5. CONNECT OUTLET RADIATOR HOSE
(a) Connect the outlet radiator hose.
6. INSTALL FAN SHROUD (w/ Trailer Towing System)
(a) Install the fan pulley to the water pump.
(b) Place the fan shroud together with the fluid coupling fan between the radiator and engine.
NOTICE:
Be careful not to damage the radiator core.
(c) Install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as
possible by hand.
(d) Attach the shroud claws to the radiator as shown in
the illustration.
(e) Install the shroud with the 2 bolts.
Torque: 6.5 N·m (66 kgf·cm, 58 in·lbf)
(f) Pass the 2 hoses through the flexible hose clamp and
close the clamp as shown in the illustration.
HINT:
Install hose clamp on center of white paint and install the
lock section of the hose clamp into the stopper of the fan
shroud.
(g) Connect the reservoir hose.
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16. (h) Install the fan and generator V-belt .
(i) Tighten the 4 nuts of the fluid coupling fan.
Torque: 29 N·m (296 kgf·cm, 21 ft·lbf)
7. INSTALL FAN SHROUD (w/o Trailer Towing System)
(a) Install the fan pulley to the water pump.
(b) Place the fan shroud together with the fluid coupling fan between the radiator and engine.
NOTICE:
Be careful not to damage the radiator core.
(c) Install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as
possible by hand.
(d) Attach the shroud claws to the radiator as shown in
the illustration.
(e) Install the shroud with the 2 bolts.
Torque: 6.5 N·m (66 kgf·cm, 58 in·lbf)
(f) Connect the reservoir hose.
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