RADIATOR INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


    1. Engage the 2 guides.

    2. Engage the 3 claws and install the fan assembly to the radiator assembly.

      Note

      Do not damage the radiator assembly when installing the fan assembly.

    3. Install the 2 lower radiator supports to the radiator assembly.

    4. B000HZR

      Install the radiator assembly with the fan assembly to the vehicle.

      Note

      Do not apply excessive force to the condenser assembly or pipe when installing the radiator assembly.

    5. Install the condenser assembly to the radiator assembly with the 4 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    6. Engage the 2 clamps.

    7. Connect the cooling fan motor connector and No. 2 cooling fan motor connector.

  2. INSTALL UPPER RADIATOR SUPPORT


    1. Install the 2 radiator support cushions to the radiator assembly.

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

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

    3. Engage the clamp and connect the hood lock control cable assembly to the upper radiator support.

    4. Connect the 2 horn connectors.

  3. INSTALL HOOD LOCK ASSEMBLY (for TMC, TMMR Made)

    for LHD: Click here

    for RHD: Click here

  4. INSTALL HOOD LOCK ASSEMBLY (for TMMK Made)


    1. B000IN7

      Apply MP grease to the sliding areas of the hood lock assembly.

    2. Connect the hood lock control cable assembly.

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

      Torque:
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      Hood Lock Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. w/ Engine Hood Courtesy Switch:


      1. Connect the connector.

    5. Install a new hood lock nut cap.

  5. CONNECT OUTLET NO. 1 OIL COOLER HOSE (w/ Oil Cooler)


    1. Connect the outlet No. 1 oil cooler hose and slide the clip to secure it.

  6. CONNECT INLET NO. 1 OIL COOLER HOSE (w/ Oil Cooler)


    1. Connect the inlet No. 1 oil cooler hose and slide the clip to secure it.

  7. CONNECT NO. 2 RADIATOR HOSE


    1. Engage the clamp and connect the No. 2 radiator hose to the fan assembly.

    2. Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

  8. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.

  9. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Install the radiator reserve tank assembly with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the radiator reserve tank hose.

  10. INSTALL INLET AIR CLEANER ASSEMBLY

  11. INSTALL FRONT BUMPER ASSEMBLY

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  13. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. B000J9RE01
      Text in Illustration
      *a Code Mark

      Slowly fill the radiator assembly with engine coolant.

      Specified Capacity
      Code Mark "M" 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Code Mark "G" 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Code Mark "Z" 7.3 liters (7.7 US qts, 6.4 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).

    3. Remove the reserve tank cap.

    4. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

    5. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

      If the engine coolant level is low, add engine coolant.

    6. Install the radiator cap sub-assembly and reserve tank cap.

    7. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the cooling system.

        CAUTION:

        When squeezing the No. 1 radiator hose and No. 2 radiator hose:


        • Wear protective gloves.

        • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

        • Keep your hands away from the fan and No. 2 fan.

        Note


        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

        • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

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

    9. Add engine coolant to the full line on the radiator reserve tank assembly.

  14. INSPECT FOR COOLANT LEAK

    Note

    Before performing each inspection, turn the A/C switch off.


    1. B000HO1

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

    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 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 cylinder head.

  15. INSTALL ENGINE UNDER COVER LH

  16. INSTALL ENGINE UNDER COVER RH

  17. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

  18. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH