RADIATOR INSTALLATION


  1. CONNECT OIL TUBE (for Automatic Transmission)

    A01BDXS

    1. Connect the 2 oil tubes to the radiator.

  2. INSTALL RADIATOR ASSEMBLY


    1. A01BC8Q

      Install the radiator assembly onto the vehicle.

      Note

      Do not drop the radiator assembly.

  3. CONNECT NO. 6 RADIATOR HOSE

    A01BGUU

    1. Connect the No. 6 radiator hose onto the radiator.

  4. CONNECT NO. 3 RADIATOR HOSE

    A01BASC

    1. Connect the No. 3 radiator hose onto the radiator.

  5. CONNECT NO. 5 RADIATOR HOSE

    A01BEQ3

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

  6. CONNECT RADIATOR HOSE OUTLET

    A01BBTG

    1. Connect the radiator hose outlet onto the radiator.

  7. INSTALL NO. 2 FAN SHROUD


    1. A01BHKEE02

      Install the No.2 fan shroud with the 2 bolts.

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

      Note

      Do not drop the radiator assembly.

  8. INSTALL FAN SHROUD


    1. A01BAEU

      Install the fan shroud with the 6 bolts.

      Torque:
      5.4 N*m  { 53 kgf*cm, 48 in.*lbf }

      Note

      Do not drop the radiator assembly.

    2. Connect the 2 reserve tank hoses.

    3. Connect the 4 radiator hoses.

  9. CONNECT OIL TUBE (for Automatic Transmission)

    A01BBA4

    1. Connect the 2 oil tubes.

  10. INSTALL COOLING FAN ECU

    A01BGBM

    1. Install the cooling fan ECU with the 2 bolts and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the 4 connectors to the cooling fan ECU. (w/ Air Conditioning)

    3. Connect the 2 connectors to the cooling fan ECU. (w/o Air Conditioning)

  11. INSTALL INTERCOOLER ASSEMBLY


    1. Temporarily install the intercooler with the 3 bolts.

    2. Connect the No. 3 air hose and tighten the 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 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 }
      A01BGT7E01

  12. INSTALL RADIATOR SUPPORT UPPER

    A01BCC9

    1. Install the radiator support upper and hood lock support brace with the 7 bolts and 2 screws.

      Torque:
      Hood Lock Support Brace x Front Bumper Reinforcement
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      except Hood Lock Support Brace x Front Bumper Reinforcement
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Install the hood lock cable.

  13. 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 }

  14. INSTALL FRONT BUMPER

  15. INSTALL STEP PLATE COVER LH

  16. INSTALL STEP PLATE COVER RH

    Tech Tips

    Use the same procedures as for the LH side.

  17. 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 }

  18. AIRTIGHT CHECK


    1. Apply some soapy water to the junction of the radiator tank lower, radiator tank upper and radiator core.

    2. Remove the radiator reservoir cap.

    3. Attach the radiator cap tester.

    4. Check if the radiator assembly is airtight by pumping the radiator cap tester.

  19. 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 }

  20. INSTALL NO. 1 AIR INLET DUCT

    A01BFWL

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

  21. INSTALL NO. 2 AIR INLET DUCT

    A01BEKK

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

  22. INSTALL RADIATOR GRILLE

  23. 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.

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  25. 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.

  26. 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.