RADIATOR INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


    1. A0136N0

      Install the 2 radiator support cushions and 2 radiator lower supports to the radiator assembly.

    2. A0136HZ

      Install the fan assembly to the radiator assembly, engage the claw and bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    3. A01391F

      Connect the radiator tank reserve hose to the radiator assembly.

  2. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Install the front cross member sub-assembly with the 6 bolts.

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

  3. CONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Install the radiator assembly with the 2 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  4. CONNECT RADIATOR OUTLET HOSE


    1. A0135SS

      Connect the radiator outlet hose with the clamp.

    2. A0138PV

      Connect the radiator outlet hose to the fan shroud with the clamp.

  5. CONNECT RADIATOR INLET HOSE


    1. A0138Y2

      Connect the radiator inlet hose with the clamp.

  6. CONNECT COOLING FAN MOTOR CONNECTOR


    1. A0136SA

      Connect the cooling fan motor connector and the cooling fan motor connector clamp.

  7. ADD ENGINE COOLANT


    1. Connect the engine side radiator outlet hose .

    2. A0137DX

      Install the cylinder block drain cock plug.

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

    3. Pour engine coolant into the radiator assembly until it is full.

      Capacity
      Specification Capacity
      except Tropic Spec 4.0 liters (4.2 US qts, 3.5 Imp qts)
      for Tropic Spec 4.4 liters (4.6 US qts, 3.9 Imp qts)

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant 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 engine 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).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. Install the radiator cap sub-assembly securely.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

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

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

      3. Maintain the engine speed at 2500 to 3000 rpm and warm up the engine until the cooling fan operates.

      4. Press the outlet radiator hose and inlet radiator hose several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. Stop the engine and wait until the coolant cools down.

    9. If the engine coolant level is below the full level, perform steps (c) through (h) and repeat the operation until the engine coolant level stays the full level.

    10. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.

  8. INSPECT FOR ENGINE COOLANT LEAKS

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator 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.


    1. A01375K

      Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

    2. Warm up the engine.

    3. Pump it to 137 kpa (1.4 kgf*cm2, 19.9 psi), 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.

    4. Be sure not to put more than 177 kpa (1.8 kgf*cm2, 25.6 psi).

  9. INSTALL SUPPORT LH SUB-ASSEMBLY

  10. INSTALL SUPPORT RH SUB-ASSEMBLY

  11. INSTALL FRONT BUMPER COVER

    A0136YZ

    1. Install the 2 clips.

    2. A01360O

      Engage the 13 claws and install the front bumper cover.

    3. A013716E01

      Tighten the 3 bolts and 5 screws.

    4. Install the 3 clips.

    5. Remove the protective tape.

  12. INSTALL ENGINE UNDER COVER


    1. A013649

      Install the engine under cover with the 5 screws.

    2. Install the 9 bolts.