RADIATOR REMOVAL

PROCEDURE

1. Click here

   REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

   Click here

2. Click here

   DRAIN ENGINE COOLANT

   Click here

3. Click here

   REMOVE RADIATOR SIDE DEFLECTOR

   
   

   • for Steel Type Bumper:

     Click here

   • for Resin Type Bumper:

     Click here

4. Click here

   REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

5. Click here

   REMOVE NO. 1 RADIATOR AIR GUIDE

   
   
   1. 

      Remove the 4 clips and No. 1 radiator air guide.

      Note:

      Do not reuse the clip.

6. Click here

   REMOVE NO. 4 AIR HOSE

   
   
   1. 

      Detach the 2 clamps to disconnect the oil return hose from the No. 4 air hose.

   2. Loosen the 2 hose clamps and remove the No. 4 air hose.

7. Click here

   REMOVE NO. 2 AIR TUBE

   
   
   1. 

      Detach the 4 clamps to disconnect the oil return hose from the No. 2 air tube.

   2. Loosen the hose clamp and remove the 2 bolts and No. 2 air tube.

8. Click here

   REMOVE NO. 1 RADIATOR HOSE

   
   
   1. 

      Slide the 2 hose clamps and remove the No. 1 radiator hose.

9. Click here

   DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

   
   
   1. 

      Detach the clamp to disconnect the pressure feed tube assembly from the fan shroud.

   2. Detach the claw and disconnect the vane pump oil reservoir assembly from the No. 1 oil reservoir bracket as shown in the illustration.

10. Click here

    REMOVE NO. 1 OIL RESERVOIR BRACKET

    
    
    1. 

       Remove the 3 bolts and No. 1 oil reservoir bracket.

11. Click here

    REMOVE RADIATOR RESERVOIR

    
    
    1. 

       Detach the clamp to disconnect the No. 2 water by-pass hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 2 water by-pass hose from the radiator assembly.

    3. 

       Slide the hose clamp and disconnect the water by-pass hose from the radiator assembly.

    4. Remove the 2 bolts and radiator reservoir.

12. Click here

    REMOVE VISCOUS HEATER V BELT (w/ Viscous Heater)

    Click here

13. Click here

    DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

    
    
    1. 

       Slide the hose clamp and disconnect the No. 1 oil cooler outlet hose from the radiator assembly.

14. Click here

    DISCONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)

    
    
    1. 

       Detach the clamp to disconnect the No. 1 oil cooler inlet hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 1 oil cooler inlet hose from the radiator assembly.

15. Click here

    REMOVE FAN SHROUD

    
    
    1. 

       Detach the 6 wire harness clamps.

    2. 

       Loosen the 4 nuts holding the fan with fluid coupling assembly.

    3. Remove the fan and generator V belt.

       Click here

    4. 

       Detach the 2 claws and 2 guides to disconnect the fan shroud from the radiator assembly.

    5. Remove the 4 nuts of the fan with fluid coupling assembly and remove the fan shroud together with the fluid coupling assembly.

       Note:

       Do not allow the radiator assembly to interfere with other parts.

    6. Remove the fan pulley from the engine water pump assembly.

16. Click here

    DISCONNECT NO. 2 RADIATOR HOSE

    
    
    1. 

       Slide the hose clamp and disconnect the No. 2 radiator hose from the radiator assembly.

17. Click here

    REMOVE RADIATOR ASSEMBLY

    
    
    1. 

       Remove the 4 bolts.

    2. 

       w/ Air Conditioning System:

       Detach the 2 claws and 2 guides to disconnect the cooler condenser assembly from radiator assembly.

       Note:
       

       • Do not allow the radiator assembly to interfere with other parts.

       • Do not apply any excessive force to the cooler condenser assembly and cooler pipe.

    3. Remove the radiator assembly from the vehicle.

18. Click here

    REMOVE RADIATOR PROTECTOR (w/o Air Conditioning System)

    
    
    1. 

       Detach the 2 claws and 2 guides to remove the radiator protector.

19. Click here

    REMOVE RADIATOR DRAIN COCK PLUG

    
    

    1. Remove the radiator drain cock plug from the radiator assembly.

    2. Remove the O-ring from the radiator drain cock plug.