RADIATOR > INSTALLATION

for Preparation Click here



1. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL


    A205319E01

  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.



2. 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.



3. INSTALL RADIATOR ASSEMBLY


    A201662

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

  1. Install the 2 cushions and 2 grommets.



    A212147

  1. Engage the 2 claws on the condenser 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.

  1. Install the bolt to the ECM.

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

  1. Engage the 3 clamps and connect the 3 connectors.

  1. Engage the claw and install the piping clamp.



4. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

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

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

  1. Connect the wire harness clamp.

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



5. INSTALL RADIATOR LOWER NO. 1 AIR DEFLECTOR

  1. Insert the 2 guides and install the radiator air deflector.

  1. Install the 2 clips.



6. INSTALL HIGH PITCHED HORN ASSEMBLY

  1. Install the horn with the bolt.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Connect the horn connector.



7. CONNECT NO. 2 RADIATOR HOSE


    A201672E03

  1. Connect the radiator hose to the radiator assembly with the hose clamp.
    Text in Illustration 
    *a
    		View A
    *b
    		Upper Side
    *c
    		White Paint Mark
    *d
    		Projection On Radiator

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



8. CONNECT NO. 3 RADIATOR HOSE


    A201668E04

  1. Connect the radiator hose to the radiator assembly with the hose clamp.
    Text in Illustration 
    *a
    		View A
    *b
    		Upper Side
    *c
    		White Paint Mark
    *d
    		Projection On Radiator

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



9. CONNECT RADIATOR RESERVOIR TANK HOSE


    A201669E03

  1. Connect the radiator reservoir tank hose to the radiator reservoir with the hose clamp.
    Text in Illustration 
    *a
    		View A
    *b
    		Front Side

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

  1. Engage the hose clamp.



10. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    A198883

  1. Install the air cleaner filter element as shown in the illustration.



11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

  1. Align the 2 hinges with the guides on the case and engage them in the grooves.

  1. Install the air cleaner cap with the 2 clamps.



    A205327E03

  1. Connect the air cleaner hose as shown in the illustration.
    Text in Illustration 
    *a
    		View A
    *b
    		Upper Side
    *c
    		Front Side
    *d
    		Recession
    *e
    		Protrusion

    HINT:
    The clamp should contact the air cleaner hose stopper.



12. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY


B213663

  1. Engage the 2 guides and install the front bumper reinforcement

  1. Tighten the 8 bolts.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }



    B213662

  1. Engage the 5 clamps.



13. INSTALL WINDSHIELD WASHER JAR ASSEMBLY


E178089

  1. Connect the connectors.

  1. Connect the washer hose.

  1. Engage the guide and install the windshield washer jar.

  1. Engage the claw.

  1. Tighten the 2 bolts.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }



14. INSTALL RADIATOR SUPPORT EXTENSION LH


B213661

  1. Engage the 2 claws and install the radiator support extension.



15. INSTALL RADIATOR SUPPORT EXTENSION RH

HINT:
Use the same procedure as for the LH side.



16. INSTALL NO. 2 RADIATOR SIDE AIR SEAL


B213660

  1. Engage the 2 claws and install the radiator side air seal.



17. INSTALL NO. 1 RADIATOR SIDE AIR SEAL

HINT:
Use the same procedure as for the LH side.



18. INSTALL FRONT BUMPER ENERGY ABSORBER


B220545

  1. Engage the 2 guide and install the front bumper energy absorber.



19. INSTALL UPPER RADIATOR SUPPORT ABSORBER


B213658

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



20. INSTALL FRONT BUMPER ASSEMBLY
(Click here)


21. ADD ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)

  1. Tighten the water inlet drain cock plug.



    A201667

  1. Plunge the engine drain cock plug.



    A201665E01

  1. Install the water inlet clip.
    Text in Illustration 
    *1
    		Water Inlet Clip
    *2
    		Hose

  1. Disconnect the hose from the water inlet drain cock plug.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		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).

  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.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler 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.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going 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 
    *a
    		FULL Line
    *b
    		LOW Line



22. ADD ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)

  1. Tighten the radiator drain cock plug.

  1. Remove the water filler cap sub-assembly.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		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).

  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.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler 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.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going 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 
    *a
    		FULL Line
    *b
    		LOW Line



23. INSPECT FOR COOLANT LEAK

CAUTION:
To avoid the danger of being burned, do not remove the water filler 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.



    A198898E01

  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.