RADIATOR INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


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

    2. 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. Connect the radiator tank reserve hose to the radiator assembly.

  2. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. 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. 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. Connect the radiator outlet hose with the clamp.

    2. 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. 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 LEAK


    1. Start the engine.

    2. Maintain the engine speed at 1,500 rpm until the first cooling cycle (cooling fan on).

    3. Stop the engine and wait for cool down.

    4. If necessary top up the level to the maximum mark.

  9. INSTALL SUPPORT LH SUB-ASSEMBLY

  10. INSTALL SUPPORT RH SUB-ASSEMBLY

  11. INSTALL FRONT BUMPER COVER

    Click here

  12. INSTALL ENGINE UNDER COVER