RADIATOR > INSTALLATION

for Preparation Click here



1. INSTALL RADIATOR DRAIN COCK PLUG

  1. Install the radiator drain cock plug to the radiator assembly.

    NOTICE:
    Replace the O-ring if it is damaged.



2. INSTALL RADIATOR TO SUPPORT SEAL


    A205320E01

  1. Wipe off any tape adhesive residue with cleaner.

  1. Remove the release paper from the support seal.

  1. Install the 5 new support seals to the radiator.



3. INSTALL FAN SHROUD


    A201637

  1. Install the 2 pawl fittings and the fan shroud.

  1. Engage the 2 claws.



4. INSTALL RADIATOR ASSEMBLY


    A201641

  1. Install the 2 cushions and 2 grommets.



    A201634

  1. Engage the 2 claws and install the radiator assembly together with the fan shroud onto the vehicle.

    NOTICE:
    Do not apply any excessive force to the cooler condenser assembly or piping when installing the radiator assembly.



    A201633

  1. Engage the 5 wire harness clamps and connect the hose, 2 connectors.



    A201632

  1. Engage the claw and install the piping clamp.



5. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    A201625

  1. Install the radiator upper support with the 5 bolts.

    Torque:
    13 N*m{ 127 kgf*cm , 9 ft.*lbf }

  1. Connect the horn connector.



6. INSTALL RADIATOR SUPPORT UPPER ABSORBER


B213658

  1. Engage the 7 claws and install the radiator support upper absorber.



7. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY


    A201624

  1. Engage the 2 clamps and install the hood lock control cable.



8. CONNECT NO. 2 RADIATOR HOSE


    A201631E01

  1. Connect the radiator hose to the radiator assembly with the hose clamp.

    NOTICE:
    Perform the installation with the hose clip and mark at the correct angle.



9. CONNECT NO. 1 RADIATOR HOSE


    A201629E01

  1. Connect the radiator hose to the radiator assembly with the hose clamp.

    NOTICE:
    Perform the installation with the hose clip and mark at the correct angle.



10. CONNECT NO. 4 WATER BY-PASS HOSE


    A201627E01

  1. Connect the water by-pass hose to the radiator assembly with the hose clamp.

    NOTICE:
    Perform the installation with the hose clip and mark at the correct angle.



11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    A201623

  1. Install the air cleaner case with the 3 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



12. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    A202524

  1. Install the air cleaner filter element.

    NOTICE:
    Engage the air cleaner filter element protrusion with the air cleaner case groove.



13. INSTALL AIR CLEANER CAP ASSEMBLY


    A201620E01

  1. Engage the 2 claws and 2 clamps and install the air cleaner cap.

  1. Connect the connector and 2 wire harness clamps.
    Text in Illustration 
    *1
    		Wire harness clamp
    *2
    		Clamp



    A201621E01

  1. Connect the air cleaner hose to the air cleaner cap.

    HINT:
    1. The clamp should contact the air cleaner hose stopper.
    2. Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.



14. ADD ENGINE COOLANT (w/o Combustion Type Power Heater)

  1. Tighten the radiator drain cock plug.



    A201604E01

  1. Loosen the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Add TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    w/o Combustion Type Power Heater
    		4.5 liters (4.8 US qts, 4.0 Imp. qts)

    NOTICE:
    Never use water as a substitute 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 is a combination of low phosphates and organic acids).



    A202523E01

  1. Add coolant to the B line of the radiator reserve tank.
    Text in Illustration 
    *1
    		B Line

  1. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.



    A201604E01

  1. Tighten the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Install the reserve tank cap sub-assembly.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine, and wait until the engine coolant cools down.



    A202523E02

  1. After the engine has cooled down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *1
    		FULL Line
    *2
    		LOW Line



15. ADD ENGINE COOLANT (w/ Combustion Type Power Heater)

  1. Tighten the radiator drain cock plug.



    A201604E01

  1. Loosen the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Add TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    w/ Combustion Type Power Heater
    		4.9 liters (5.2 US qts, 4.3 Imp. qts)

    NOTICE:
    Never use water as a substitute 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 is a combination of low phosphates and organic acids).



    A202523E01

  1. Add coolant to B line of the radiator reserve tank.
    Text in Illustration 
    *1
    		B Line

  1. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.



    A201604E01

  1. Tighten the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Start the engine, maintain the speed at 3000 rpm for 10 seconds, and idle the engine for 10 seconds. Repeat the same procedure above 4 more times.

  1. Install the reserve tank cap sub-assembly.

  1. Loosen the air bleed valve 1 and the air bleed valve 2.

  1. Add 350 cc (21.3 cu in.) coolant.

  1. Tighten the air bleed valve 1 and the air bleed valve 2.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine, and wait until the engine coolant cools down.



    A202523E02

  1. After the engine has cooled down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *1
    		FULL Line
    *2
    		LOW Line



16. INSPECT FOR COOLANT LEAK

CAUTION:
To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.



    A201603E01

  1. Fill the radiator assembly with engine coolant, and attach a radiator cap tester.
    Text in Illustration 
    *1
    		Radiator Cap Tester

  1. Pump the tester to 118 kPa (1.2 kgf/cm2, 17.1 psi), and then check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.



17. INSTALL ENGINE UNDER COVER


A204147

  1. Install the engine under cover assembly with the 4 bolts and the 4 clips.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



18. INSTALL FRONT BUMPER COVER

  1. Install the front bumper cover (Click here).