SUB RADIATOR INSTALLATION


  1. INSTALL NO. 2 W/ MOTOR FAN ASSEMBLY


    1. Install the w/ motor fan assembly No.2 onto the sub radiator assembly with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  2. INSTALL NO. 5 RADIATOR HOSE

    A01BHUN

    1. Install the No. 5 radiator hose onto the sub radiator.

  3. INSTALL SUB RADIATOR ASSEMBLY

    A01BBQ3

    1. Install the 2 grommets.

    2. A01BF9CE02

      Install the sub radiator assembly with the bolt.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

    3. Connect the fan connector.

  4. CONNECT NO. 6 RADIATOR HOSE

    A01BFBF

    1. Connect the No. 6 radiator hose to the sub radiator.

  5. CONNECT NO. 5 RADIATOR HOSE

    A01BGRA

    1. Connect the No. 5 radiator hose to the radiator.

  6. INSTALL HIGH PITCHED HORN ASSEMBLY (for Narrow Body)

  7. INSTALL RADIATOR SUPPORT UPPER

    A01BFEY

    1. Install the radiator support upper with the 6 bolts and 2 screws.

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

    2. Install the hood lock cable.

  8. INSTALL NO. 2 RADIATOR AIR GUIDE (for Wide Body)

    A01BBWO

    1. Install the No. 2 radiator air guide with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  9. INSTALL FRONT BUMPER

  10. INSTALL STEP PLATE COVER RH

  11. INSTALL STEP PLATE COVER LH

  12. INSTALL RADIATOR RESERVE TANK ASSEMBLY

    A01BDJB

    1. Install the radiator reserve tank assembly with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  13. INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY

    A01BEZD

    1. Install the windshield washer motor and pump assembly with the 2 bolts.

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

  14. INSTALL NO. 1 AIR INLET DUCT

    A01BFWL

    1. Install the No. 1 air inlet duct with the 2 bolts and 2 clips.

  15. INSTALL NO. 2 AIR INLET DUCT

    A01BEKK

    1. Install the No. 2 air inlet duct with the 3 clips.

  16. INSTALL RADIATOR GRILLE

  17. ADJUST HOOD SUB-ASSEMBLY


    1. A01BC5A

      Loosen the bolts to adjust the hood front and back, side to side.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Perform this procedure after replacement of the centering bolts with the supplied ones.

    2. A01BDOJ

      Turn the cushion to adjust the hood gap.

    3. A01BDA2

      Loosen the hood lock to adjust the hood front up and down, side to side.

      Torque:
      12 N*m  { 122 kgf*cm, 9.0 ft.*lbf }

      Note

      Perform this procedure after replacement of the centering bolts with the supplied ones.

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  19. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with coolant to the top of the inlet.

      Coolant capacity
      Condition Capacity
      w/ rear heater 18.2 liters (19.2 US qts, 16.0 lmp. qts)
      w/o rear heater 16.2 liters (17.0 US qts, 14.0 lmp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only 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 (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly install the bleeder plug.

    5. A01BGFB

      Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  20. INSPECT FOR ENGINE COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      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 cylinder head.