Toyota Celica 1986-1993 Repair Guide

Intercooler

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The 1988-89 Celicas with the 3S-GTE engine have a separate water cooling system for the intercooler and turbocharger. The small sub-radiator has its own draincock and the system has its own expansion tank. These are drained and filled separately from the engine cooling system. The 1990-93 Celicas with the 3S-GTE engine have an air-cooled intercooler system.



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Fig. Fig. 1 The 1988-89 Celica with the 3S-GTE engine has an intercooler that has its own radiator, which must be drained separately



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Fig. Fig. 2 Checking the intercooler coolant level on the 1988-89 Celica with the 3S-GTE engine



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Fig. Fig. 3 Turbocharger cooling system components1988-89 Celica with the 3S-GTE engine

FLUID RECOMMENDATIONS



Use a 50/50 mix of ethylene-glycol coolant and water, not an alcohol type coolant. Do NOT use coolant that has already been used in the engine cooling system. Change this coolant as often as the engine coolant is changed.

DRAIN, FLUSH AND REFILL



  1. Drain the coolant from the intercooler by opening the separate draincock on the intercooler radiator.
  2.  
  3. If desired, flush the cooling system after it has drained.
    1. Using a garden hose, fill the intercooler system and allow the water to run out the draincock. Continue until the water runs clear.
    2.  
    3. If the system is badly contaminated with rust or scale, use a commercial cleaner to clean it out. Follow the manufacturer's instructions.
    4.  
    5. Some common causes of extremely dirty systems are air in the system, poor maintenance or failure to change coolant, leaks, use of excessively hard or soft water or failure to use the correct mixture of antifreeze and water.
    6.  

  4.  
  5. Close the draincocks without overtightening them.
  6.  
  7. Using fresh, ethylene glycol based anti-freeze, prepare a container of coolant which is 50% water and 50% antifreeze. Slightly more antifreeze may be added for special conditions but must never exceed 70% of the solution. The use of de-mineralized or distilled water is recommended to eliminate corrosion and deposits in the system. The intercooler system holds about 1.8 quarts, or 1.7 liters.
    1. Pour the coolant mixture into the intercooler tank until it is full.
    2.  
    3. Turn the ignition key to the On position, press the accelerator pedal and release it. This causes the intercooler water pump to operate and circulate the coolant within the system. Turn the ignition Off and top up the fluid level.
    4.  
    5. Repeat the ignition onpump the pedalcheck the level sequence several times until the level no longer drops in the tank. Always turn the key Off before checking the coolant level; the level will drop when the pump is running.
    6.  
    7. Make certain you have refilled the main cooling system. Install the intercooler cap and start the engine. After a minute of low rpm warm up, gun the engine to about 3,000 rpm. Do this several times, then shut the engine off.
    8.  
    9. Carefully remove the cap from the intercooler tank and check the coolant level, topping it up as needed.
    10.  
    11. Wait 20 minutes (engine and ignition off) and repeat step b (above) once or twice. Top off the coolant as needed and install the intercooler cap. Check for any leaks.
    12.  

  8.  


WARNING
If the intercooler is not filled to capacity, its performance will suffer. Double check that all the air is removed. Additionally, if the fluid level drops too far within the intercooler, the pump will not operate due to a built-in safety system.

 
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