RADIATOR (for 2WD) INSTALLATION


  1. INSTALL RADIATOR SUPPORT LOWER


    1. Install the 2 radiator support lowers.

  2. INSTALL RADIATOR SUPPORT CUSHION


    1. Install the 2 radiator support cushions.

  3. INSTALL FAN SHROUD WITH FAN AND MOTOR


    1. A01GMNA

      Install the fan shroud with fan and motor to the radiator, and attach the 3 claws.

  4. INSTALL RADIATOR ASSEMBLY


    1. A01GMY5E02
      Text in Illustration
      *1 Packing

      Install the radiator to the front crossmember together with the fan shroud with fan motor.

      Note

      Do not allow the radiator to interfere with other parts.

      Tech Tips

      Install the lower packing as shown in the illustration.

    2. Align the radiator with the cooler condenser, and then install the 4 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
  5. INSTALL HOOD LOCK ASSEMBLY


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

  6. INSTALL HOOD LOCK CONTROL CABLE COVER


    1. Connect the wire harness clamp.

    2. Connect the hood lock control cable to the hood lock control cable cover.

    3. Attach the guide to install the hood lock control cable cover.

  7. INSTALL RADIATOR UPPER SUPPORT SUB-ASSEMBLY


    1. Connect the 3 connectors and attach the 5 wire harness clamps to connect the wire harness.

    2. Install the radiator upper support with the 5 bolts.

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


    1. Attach the 8 wire harness clamps to the fan shroud, and connect the 3 connectors.

  9. CONNECT HOOD LOCK ASSEMBLY


    1. Connect the connector.

    2. Connect the hood lock assembly with the 2 bolts and lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. Install the lock nut cap.

  10. CONNECT HOOD LOCK CONTROL CABLE COVER


    1. Connect the hood lock control cable cover with the 3 screws and attach the claw.

  11. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    A01GHVYE01

    1. Connect the connector.

    2. Attach the 2 guides and install the millimeter wave radar sensor assembly with the 3 bolts in alphabetical order.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
  12. INSTALL ENGINE ROOM ECU OUTLET DUCT


    1. Install the engine room ECU outlet duct.

  13. CONNECT NO. 1 OIL COOLER OUTLET HOSE


    1. Connect the No. 1 oil cooler outlet hose to the radiator.

  14. CONNECT NO. 1 OIL COOLER INLET HOSE


    1. Connect the No. 1 oil cooler inlet hose to the radiator.

  15. INSTALL NO. 2 RADIATOR HOSE


    1. A01GNAHE01
      Text in Illustration
      *a Front
      *b Upper
      *c RH Side

      Install the No. 2 radiator hose to the radiator and water inlet, and then secure it with the hose clamps.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  16. INSTALL NO. 1 RADIATOR HOSE


    1. A01GITGE01
      Text in Illustration
      *1 Radiator Hose
      *2 Hose Clamp
      *3 Stopper
      *a Upper
      *b RH Side
      *c LH Side
      *d 1.0 to 5.0 mm (0.0393 to 0.196 in.)

      Install the No. 1 radiator hose to the radiator and water outlet, and then secure it with the hose clamps.

      Tech Tips


      • The direction of the hose clamp is indicated in the illustration.

      • Insert the radiator hose into the stopper. Set the hose clamp so that the clearance between the hose clamp and the stopper is within 1.0 to 5.0 mm (0.0393 to 0.196 in.).

  17. INSTALL RADIATOR RESERVOIR ASSEMBLY


    1. Install the radiator reservoir assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01GMZHE01
      Text in Illustration
      *a Upper

      Connect the 2 reservoir hoses.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  18. ADD ENGINE COOLANT

    Standard Capacity
    Item Radiator Core Thickness [mm] Specified Condition
    for 2WD 16 11.0 liters (11.6 US qts, 9.7 Imp. qts)
    27 11.8 liters (12.5 US qts, 10.4 Imp. qts)
    for AWD 16 11.1 liters (11.7 US qts, 9.8 Imp. qts)

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Before adding coolant, turn the A/C switch off.


    1. Tighten the radiator drain cock plug.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. Add TOYOTA Super Long Life Coolant (SLLC) into the radiator reservoir.

      Capacity
      5.0 liters (5.3 US qts, 4.4 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).

      • Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

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

    4. Further add coolant into the radiator reservoir until it reaches the FULL line.

    5. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level.

      If the coolant level is low, add coolant.

    6. Using a 6 mm hexagon wrench, install the vent plug.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    7. Bleed air from the cooling system.

      Note

      Before starting the engine to warm up the engine, turn the A/C switch off.


      1. While idling the engine for approximately 10 minutes, make sure the coolant remains at the FULL line by adding coolant as necessary.

      2. A01GJEM

        After idling the engine for 10 minutes, add coolant until it reaches the B line.

        Capacity
        Approximately 2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp. qts)
        Text in Illustration
        A01GKOV B Line

        Tech Tips

        The B line is the lower edge of the inner wall of the filler neck.

      3. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.

        CAUTION:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fans.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the SLLC starts to flow inside the hose.

    8. Stop the engine and wait until the coolant cools down to ambient temperature.

    9. Check the coolant level.

      If the coolant level is below the FULL line, add coolant until it reaches the FULL line.

  19. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  20. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before each inspection, turn the A/C switch OFF.


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

      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 head.

  21. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    A01GMOKE01

    CAUTION:

    Exposure to radio frequency emissions is hazardous to your health. It is hazardous to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

    Note


    • This device complies with FCC radio frequency emission regulations.

    • Perform measurements on a level surface.

    • Make sure that no large pieces of metal are within a 10 m (32.8 ft.) x 14 m (45.9 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.


    1. Before adjusting the radar beam axis, prepare the vehicle as follows.


      1. Check the tire pressure and adjust it if necessary.

      2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

    2. w/ Air Suspension:

      Adjust the vehicle's height to the standard height.

    3. Check and adjust the vertical direction of the radar sensor.


      1. A01GNRJE01

        Remove dust, oil and foreign matter from the radar sensor's level rack.

      2. Set a level on the radar sensor's level rack.

      3. A01GL2BE01

        Check that the level's air bubble is within the red frame.

        OK
        Level's air bubble is within red frame.

        If the bubble is not within the red frame, use a hexagon wrench to adjust bolt A until the level's air bubble is within the red frame.

        Tech Tips


        • The adjustable range within the red frame of the level is +/-0.2°.

        • The target angle is +0.2° (upward angle of 0.2°).

        Result
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Vertical adjustment
        • Upward direction: Turn bolt A in minus (-) direction

        • Downward direction: Turn bolt A in plus (+) direction

        For 1 complete turn of screwdriver, sensor moves about 0.12°
    4. A01GK74E01

      Adjust the reflector height.


      1. Adjust the reflector so that the center of the SST reflector is the same height as the millimeter wave radar sensor.

        SST
        09870-60000   ( 09870-60010 )
        09870-60040

        Tech Tips

        Prepare a 10 m (32.8 ft.) string with a sharp-pointed weight (plumb bob) and a 5 m (16.4 ft.) tape measure.

    5. Place the reflector.


      1. From the center of the front bumper (center of the emblem), hang a weight with a pointed tip, and mark point B on the ground.

        A01GM2HE01
      2. From the center of the rear bumper (center of the emblem), hang a weight with a pointed tip, and mark point A on the ground.

        A01GJIME01
      3. Using a piece of string that uses point A as a starting point and that passes through point B, make a straight line on the ground ahead of the vehicle 5 m (16.4 ft.) or more from point B.

        Tech Tips


        • Make sure to secure the string (using tape, etc.) when it is taut.

        • Lightly flick the string with your fingers several times to confirm that the string is aligned above point B.

      4. Using a tape measure, measure 10 mm (0.394 in.) to the left of the 5000 mm (16.4 ft.) position. Place the reflector at that position.

        Note

        Perform the operation as precisely as possible.

        A01GLM1E01
    6. Check the radar beam axis.


      1. When using the intelligent tester:


        1. Connect the intelligent tester to the DLC3.

        2. Turn the engine switch on (IG).

        3. Turn the intelligent tester main switch ON and turn the cruise control main switch ON.

        4. Select "Auto" from the intelligent tester display screen. *1

        5. Select "Radar Cruise" from the display screen.

        6. Select the appropriate menu item.


          1. For vehicles with lane recognition camera: select "w/ LKA System" from the display screen.

          2. For vehicles without lane recognition camera: select "w/o LKA System" from the display screen.

        7. Select "Radar Cruise" from the display screen.

        8. Select "Utility" from the display screen.

        9. Select "Beam Axis Adjustment" from the display screen.

        10. Select "Next".

        11. Select "Next".

        12. Select "Next".

          Note


          • Turn the cruise control main switch ON before pressing Next.

          • Make sure there is a distance of at least 20 cm (7.87 inches) between the radar sensor and any nearby individuals.

            CAUTION:

            Do not come within 20 cm (7.87 inches) of the radar sensor.

        13. Check the following items on the laser cruise divergence data screen.

          CAUTION:

          While using the intelligent tester's beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the intelligent tester's data. In such a case, the deviation is displayed on the combination meter's multi-information display.


          1. Confirm that the distance value is approximately 5 m (16.4 ft.).

            Tech Tips


            • A value between 0.0 and 6.3 m (20.7 ft.) is indicated.

            • If the distance is 0 m (0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the NOTICE at the beginning of this adjustment procedure).

          2. Confirm that the left/right side value is between 0.0 and 6.3°.

            Tech Tips

            If the distance is 0 m (0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the NOTICE at the beginning of this adjustment procedure).

    7. Check and adjust the horizontal direction of the radar sensor.


      1. Check that the divergence of the radar beam axis is 0°.

        Standard
        0° (Both right and left)

        If the axis is not as specified, use a hexagon wrench to adjust bolt B until the divergence of the radar beam axis is 0°.

      2. A01GJUVE01

        Based on the measured divergence of the beam axis, turn and adjust bolt B for horizontal adjustment of the millimeter wave radar sensor using a hexagon wrench.

        Result
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Horizontal adjustment
        • Right direction: Turn bolt B in plus (+) direction

        • Left direction: Turn bolt B in minus (-) direction

        For 1 complete turn of screwdriver, sensor moves about 0.07°

        Tech Tips

        If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.

      3. Select "Next". The driving learning value is automatically reset.

        Tech Tips

        A buzzer will sound for 10 seconds.

      4. Disconnect the intelligent tester from the DLC3.

    8. Recheck and readjust the vertical direction of the radar sensor.


      1. A01GNRJE01

        Set a level on the radar sensor's level rack.

      2. A01GL2BE01

        Check that the level's air bubble is within the red frame.

        OK
        Level's air bubble is within the red frame.

        If the bubble is not within the red frame, use a hexagon wrench to adjust bolt A until the level's air bubble is within the red frame.

        Tech Tips


        • The adjustable range within the red frame is +/-0.2°.

        • The target angle is +0.2° (upward angle of 0.2°).

        Result
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Vertical adjustment
        • Upward direction: Turn bolt A in minus (-) direction

        • Downward direction: Turn bolt A in plus (+) direction

        For 1 complete turn of screwdriver, sensor moves about 0.12°
  22. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 13 screws and 7 clips.

  23. INSTALL NO. 1 AIR CLEANER INLET


    1. A01GIR0E02

      Align the holes with the connection areas labeled A, and attach the No. 1 air cleaner inlet.

    2. Install the No. 1 air cleaner inlet with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  24. INSTALL V-BANK COVER SUB-ASSEMBLY

    A01GLQ5E01

    1. After sliding the cover from the vehicle front to the rear to attaching the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

  25. INSTALL FRONT BUMPER REINFORCEMENT

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