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 OIL COOLER HOSE (for Automatic Transmission)


    1. Install the outlet oil cooler hose to the radiator assembly, and slide the hose clamp to secure the hose.

    2. Install the inlet oil cooler hose to the radiator assembly, and slide the hose clamp to the secure the hose.

  3. 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.

  4. 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 damage the radiator assembly when installing the No. 2 fan shroud.

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

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

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

  5. 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.

  6. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the radiator assembly, and slide the hose clamp to secure the hose.

  7. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the radiator assembly, and slide the hose clamp to secure the hose.

  8. CONNECT OIL COOLER HOSE (for Automatic Transmission)


    1. Connect the outlet oil cooler hose to the oil cooler tube, and slide the hose clamp to secure the hose.

    2. Connect the inlet oil cooler hose to the oil cooler tube, and slide the hose clamp to secure the hose.

    3. Attach the 2 oil cooler hose clamps.

  9. INSTALL FAN BRACKET ASSEMBLY


    1. w/o Air Conditioning System:


      1. Install the fan bracket assembly together with the No. 1 cooling fan ECU with the 2 bolts and 2 nuts.

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

      2. Connect the 2 connectors to the No. 1 cooling fan ECU.

    2. w/ Air Conditioning System:


      1. Install the fan bracket assembly together with the No. 1 and No. 2 cooling fan ECUs with the 2 bolts and 2 nuts.

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

      2. Connect the 4 connectors to the No. 1 and No. 2 cooling fan ECUs.

  10. 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 }

  11. 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 }

  12. 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.

  13. 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 }

  14. 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 washer hose to the windshield washer motor and pump assembly.

    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.

  15. 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.

  16. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 2 clips and 4 bolts.

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

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


    1. A003FXZE01
      Text in Illustration
      *a Upper Side of Vehicle
      *b Left Side of Vehicle

      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 upward as shown in the illustration.

  18. INSTALL CONDENSER WITH RECEIVER ASSEMBLY (w/ Air Conditioning System)

    Click here

  19. INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. A003DDAE02
      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 }

  20. INSTALL FRONT BUMPER REINFORCEMENT


  21. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block water drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

      Standard Capacity
      Item Specified Condition
      w/o Rear Heater 11.2 liters (11.8 US qts, 9.9 Imp. qts)
      w/ Rear Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      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 is a combination of low phosphates and organic acids).

    4. Remove the 2-way that is located near the throttle body assembly.

    5. When air is bled and the engine coolant drains out, install the 2-way.

    6. Add coolant through the radiator reservoir assembly filler opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]

    7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note


      • Immediately after starting the engine, if the radiator reservoir assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.

      • Do not start the engine when there is no engine coolant in the radiator reservoir assembly.

      • Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough engine coolant, the engine may overheat.

      Tech Tips


      • Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.

      • The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

    9. Check the engine coolant level in the radiator reservoir assembly. [*4]

      Tech Tips


      • If the engine coolant level is below the LOW line, repeat step *1 through *4.

      • If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW lines.

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


    1. Perform vacuum purging using a vacuum pump.

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

      A003DFOE01
      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%.

  23. WARM UP ENGINE


    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.

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

  25. 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. A003I8RE02

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

    4. A003AFME01

      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.

  26. INSTALL NO. 1 ENGINE UNDER COVER