RADIATOR INSTALLATION

INSTALL RADIATOR ASSEMBLY
1. Install the 4 grommets to the radiator.
2. Install the radiator to the vehicle.
  
  Note
  
  Do not drop the radiator.
3. Connect the No. 2 radiator hose and No. 3 radiator hose.
INSTALL NO. 2 FAN SHROUD
1. Install the No. 2 fan shroud with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Note
  
  Do not drop the radiator.
2. Install the No. 2 radiator lower tank pipe with the bolt.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
INSTALL FAN SHROUD
1. Install the fan shroud with the 6 bolts.
  
  Torque:
  
  7.1 N*m { 72 kgf*cm, 63 in.*lbf }
  
  Note
  
  Do not drop the radiator.
2. w/o Air Conditioning System:
  
  Attach the 5 clamps and connect the connector.
3. w/ Air Conditioning System:
  
  Attach the 4 clamps and connect the 2 connectors.
INSTALL FAN BRACKET SUB-ASSEMBLY
1. Install the fan bracket with the 2 bolts and 2 nuts.
  
  Torque:
  
  20 N*m { 199 kgf*cm, 14 ft.*lbf }
2. Connect the clamp to the fan bracket.
CONNECT OIL COOLER TUBE (for Automatic Transmission)
1. Connect the 2 oil cooler tubes to the radiator.

INSTALL W/ RECEIVER CONDENSER ASSEMBLY (w/ Air Conditioning System)

Install the w/ receiver condenser assembly with the 4 bolts.

Note

Tighten in the order indicated in the illustration.

Tech Tips

If the condenser is replaced with a new one, add compressor oil to the new condenser.

Capacity
40 cc (1.4fl.oz.)
Compressor oil
ND-OIL 8 or equivalent

CONNECT COOLER REFRIGERANT LIQUID PIPE A (w/ Air Conditioning System)
1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the cooler refrigerant liquid pipe A.
4. Install the cooler refrigerant liquid pipe A on the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 47 in.*lbf }
5. Install the clamp with the bolt.
CONNECT COOLER REFRIGERANT DISCHARGE PIPE A (w/ Air Conditioning System)
1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the cooler refrigerant discharge pipe A.
4. Install the cooler refrigerant discharge pipe A on the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 47 in.*lbf }
INSTALL INTERCOOLER ASSEMBLY
1. Temporarily install the intercooler with the 3 bolts.
2. Connect the No. 3 air hose and tighten the hose clamp as shown in the illustration.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
  Note
  - Insert the hose until it is flush with the pipe spool end, install the clip and then check that it is securely connected.
  - Check that the hose does not interfere with any other parts.
  - Check that the hose is not twisted.
3. Connect the No. 2 air hose and tighten the hose clamp as shown in the illustration.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
  Note
  - Insert the hose until it is flush with the pipe spool end, install the clip and then check that it is securely connected.
  - Check that the hose does not interfere with any other parts.
  - Check that the hose is not twisted.
4. Tighten the 3 bolts.
  
  Torque:
  
  18 N*m { 178 kgf*cm, 13 ft.*lbf }
INSTALL NO. 2 RADIATOR AIR GUIDE (for Wide Body)
1. Install the No. 2 radiator air guide with the 2 bolts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
INSTALL NO. 1 RADIATOR AIR GUIDE (for Wide Body)
1. Install the No. 1 radiator air guide with the 2 bolts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
INSTALL RADIATOR SUPPORT UPPER
1. Install the radiator support upper with the 6 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL HOOD LOCK ASSEMBLY
1. Connect the hood lock control cable to the hood lock.
2. Install the hood lock with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY
1. Install the hood lock support brace sub-assembly with the 3 bolts.
  
  Torque:
  
  for bolt A
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL RADIATOR RESERVOIR
1. Install the radiator reservoir with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY
1. Install the windshield washer motor and pump with the 2 bolts.
  
  Torque:
  
  4.9 N*m { 50 kgf*cm, 43 in.*lbf }
PERFORM AIRTIGHTNESS CHECK
1. Apply some soapy water to the junction of the radiator tank lower, radiator tank upper and radiator core.
2. Remove the reservoir cap.
3. Attach a radiator cap tester.
4. Check if the radiator is airtight by pumping the radiator cap tester.
INSTALL NO. 1 AIR INLET DUCT
1. Install the No. 1 air inlet duct and No. 2 air inlet duct with the 2 bolts and 5 clips.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
INSTALL FRONT BUMPER
- for Standard Body Click here
- for Wide Body Click here
ADJUST HOOD SUB-ASSEMBLY
1. 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. Turn the cushion to adjust the hood gap.
3. 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.

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

ADD ENGINE COOLANT

Firmly tighten the drain plugs.

Fill the radiator reservoir with coolant to the top of the inlet.

Standard Capacity

Item	Specified Condition
w/o Heater	13.6 liters (14.4 US qts, 12.0 Imp. qts)
w/ Front Heater	14.6 liters (15.4 US qts, 12.8 Imp. qts)
w/ Front and Rear Heaters	16.6 liters (17.5 US qts, 14.6 Imp. 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).

Loosen the bleeder plug of the outlet housing.
When air is bled and the coolant drains out, firmly tighten the bleeder plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.
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.
After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

INSPECT FOR 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.
INSPECT AUTOMATIC TRANSMISSION FLUID LEVEL (for Automatic Transmission)
Tech Tips

Drive the vehicle so that the engine and transmission are at normal operating temperature.

Fluid temperature

70 to 80 °C (158 to 176 °F)
1. Park the vehicle on a level surface and set the parking brake.
2. With the engine idling and the brake pedal depressed, move shift the lever into all positions from P to L and return to the P position.
3. Take out the dipstick and wipe it clean.
4. Put it back all the way.
5. Take it out again and check that the fluid level is within the HOT range.
  
  If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add the proper amount of new fluid and recheck the fluid level.
INSPECT FOR FLUID LEAK (for Automatic Transmission)

Fluid temperature
70 to 80 °C (158 to 176 °F)

CHARGE WITH REFRIGERANT (w/ Air Conditioning System)

Perform vacuum purging using a vacuum pump.

Charge with refrigerant HFC-134a (R134a).

Standard
Single A/C
520 to 580g (18.3 to 20.5 oz.)
Dual A/C
670 to 730g (23.0 to 25.7 oz.)

SST: 07110-58060 ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

Note

Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.
Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

Tech Tips

Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.
2. Carry out the test under the following conditions:
  - Stop the engine.
  - Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
  - Repeat the test 2 or 3 times.
  - Make sure that there is some refrigerant remaining in the refrigeration system.
    
    When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
3. Using a gas leak detector, check for leakage of the refrigerant line.
4. Bring the gas leak detector close to the drain hose with the detector's power off.
  Tech Tips
  
  After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
  
  Bring the gas leak detector sensor under the drain hose.
  
  When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.
  
  If such reaction is unavoidable, the vehicle must be lifted up.
5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.
6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.
INSTALL ENGINE UNDER COVER NO. 1 (w/ Engine Under Cover No. 1)