RADIATOR INSTALLATION

PROCEDURE


  1. INSTALL RADIATOR ASSEMBLY


    1. Install the fan shroud assembly to the radiator assembly with the 2 bolts.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

      Note

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

    2. B006MTHC01
      *a Matchmark

      Align the matchmarks as shown in the illustration.

    3. Connect the 2 oil cooler hoses to the radiator assembly and slide the 2 clips to secure them.

    4. Install the oil cooler pipe with the 3 bolts.

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

    5. Install the 2 lower radiator supports.

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

    7. Connect the No. 3 air conditioner tube & accessory assembly to the fan shroud assembly with the bolt.

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

  2. INSTALL NO. 1 COOLER CONDENSER CUSHION

    Click here

  3. INSTALL COOLER CONDENSER ASSEMBLY

    Click here

  4. CONNECT NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

    Click here

  5. CONNECT NO. 3 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

    Click here

  6. INSTALL NO. 2 FAN SHROUD


    1. Engage the 2 claws.

    2. Install the No. 2 fan shroud to the radiator assembly with the 2 bolts.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

  7. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the 2 radiator support cushions.

    2. B006MZEN01

      Install the upper radiator support sub-assembly with the 5 bolts.

      Torque:
      Bolt (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Bolt (B)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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

    4. Engage the 5 clamps and connect the wire harness to the upper radiator support sub-assembly and fan shroud assembly.

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

    6. Engage the 5 clamps and connect the wire harness to the upper radiator support sub-assembly.

    7. Connect the 2 horn connectors.

    8. Engage the clamp and connect the No. 1 cooler refrigerant suction hose to the bracket.

  8. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the upper radiator support sub-assembly with the 2 bolts.

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

  9. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the radiator assembly and slide the clip to secure it.

  10. CONNECT NO. 2 WATER BY-PASS HOSE


    1. Connect the No. 2 water by-pass hose to the radiator assembly and slide the clip to secure it.

  11. CONNECT OIL COOLER HOSE


    1. B006R1VC01
      *a Matchmark

      Align the matchmarks as shown in the illustration.

    2. Connect the 2 oil cooler hoses to the oil cooler pipe and slide the 2 clips to secure them.

  12. CONNECT NO. 2 RADIATOR HOSE


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

  13. CONNECT NO. 1 RADIATOR HOSE


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

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

  14. INSTALL FRONT NO. 2 BUMPER SIDE SEAL RH (for ALPHARD)


    1. Engage the 2 claws.

    2. Install the front No. 2 bumper side seal RH with the clip.

  15. INSTALL FRONT NO. 2 BUMPER SIDE SEAL RH (for VELLFIRE)


    1. Engage the 2 claws.

    2. Install the front No. 2 bumper side seal RH with the clip.

  16. INSTALL FRONT NO. 2 BUMPER SIDE SEAL LH (for ALPHARD)


    1. Engage the 2 claws.

    2. Install the front No. 2 bumper side seal LH with the clip.

  17. INSTALL FRONT NO. 2 BUMPER SIDE SEAL LH (for VELLFIRE)


    1. Engage the 2 claws.

    2. Install the front No. 2 bumper side seal LH with the clip.

  18. INSTALL HOOD LOCK ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  19. INSTALL INLET NO. 1 AIR CLEANER

    Click here

  20. INSTALL FRONT BUMPER ASSEMBLY (for ALPHARD)

    Click here

  21. INSTALL FRONT BUMPER ASSEMBLY (for VELLFIRE)

    Click here

  22. INSTALL BATTERY

    Click here

  23. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER

    Click here

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  25. ADD ENGINE COOLANT

    Click here

  26. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  27. INSPECT FOR COOLANT LEAK

    Click here

  28. WARM UP ENGINE

    Click here

  29. INSPECT FOR REFRIGERANT LEAK

    Click here

  30. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  31. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 8 bolts and 5 clips.