RADIATOR INSTALLATION


  1. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the radiator assembly, and slide the hose clamp to secure the pipe.

  2. INSTALL RADIATOR ASSEMBLY


    1. Install the 4 grommets to the radiator assembly.

    2. Install the radiator assembly to the vehicle.

      Note

      Do not drop the radiator assembly.

    3. Connect the No. 2 radiator hose and No. 3 radiator hose to the radiator assembly, and slide the 2 hose clamps to secure each hose.

  3. INSTALL NO. 2 FAN SHROUD


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

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

      Note


      • Do not drop the radiator assembly.

      • Do not damage the radiator assembly when installing the No. 2 fan shroud.

    2. Connect the water by-pass pipe sub-assembly to the radiator assembly with the bolt.

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

    3. Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly, and slide the hose clamp to secure the hose.

  4. INSTALL FAN SHROUD


    1. Install the fan shroud with the 6 bolts.

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

      Note

      Do not drop the radiator assembly.

    2. w/o Air Conditioning System:

      Attach the 3 clamps and connect the connector.

    3. w/ Air Conditioning System:

      Attach the 2 clamps and connect the 2 connectors.

  5. INSTALL FAN BRACKET SUB-ASSEMBLY


    1. Install the fan bracket sub-assembly with the 2 bolts and 2 nuts.

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

    2. Attach the clamp.

  6. 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 }

  7. 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 }

  8. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the upper radiator support sub-assembly with the 6 bolts.

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

    2. Attach the 2 clamps to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

    3. Connect the water by-pass hose to the radiator assembly, and slide the hose clamp to secure the hose.

  9. INSTALL HOOD LOCK ASSEMBLY


    1. Connect the hood lock control cable assembly to the hood lock assembly.

    2. Install the hood lock assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. A01BDINE02
      Text in Illustration
      *A for Standard Body
      *B for Wide Body

      Install the hood lock support brace sub-assembly with the 3 bolts.

      Torque:
      for bolt A
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  11. INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY


    1. w/ Rear Wiper:

      Connect the 2 connectors and 2 washer hoses.

    2. w/o Rear Wiper:

      Connect the connector and washer hose.

    3. Attach the hose clamp.

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

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

    5. Connect the connector to the windshield washer motor and pump assembly.

  12. INSTALL RADIATOR RESERVOIR ASSEMBLY


    1. Install the radiator reservoir assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the No. 2 water by-pass hose to the radiator reservoir assembly, and slide the hose clamp to secure the hose.

    3. Connect the water by-pass hose to the radiator reservoir assembly, and slide the hose clamp to secure the hose.

  13. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 4 clips and 4 bolts.

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

  14. INSTALL RADIATOR PROTECTOR (w/o Air Conditioning System)

    A01BAV6E01
    Text in Illustration
    *a Upper Side of Vehicle
    *b Left Side of Vehicle

    1. Install the radiator protector with the 4 bolts.

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

      Note

      Make sure that the arrows are facing upwards as shown in the illustration.

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

    Click here

  16. INSTALL FRONT BUMPER REINFORCEMENT


  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. ADD ENGINE COOLANT


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

      Standard Capacity
      Item Specified Condition
      w/o Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Front Heater 13.3 liters (14.1 US qts, 11.7 Imp. qts)
      w/ Front and Rear Heaters 15.3 liters (16.2 US qts, 13.5 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).

    2. A01BGFB

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

    3. 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.

    4. A01BBOM

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

  19. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot 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 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

  20. CHARGE WITH REFRIGERANT (w/ Air Conditioning System)


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01BFDKE01
      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%.

  21. WARM UP ENGINE (w/ Air Conditioning System)


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  22. 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. A01BC1LE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. A01BCXGE01

      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.