RADIATOR INSTALLATION

PROCEDURE


  1. INSTALL RADIATOR DRAIN COCK PLUG


    1. Install a new O-ring to the radiator drain cock plug.

    2. Install the radiator drain cock plug to the radiator assembly.

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


    1. Attach the 2 guides and 2 claws to install the radiator protector to the radiator assembly.

  3. INSTALL RADIATOR ASSEMBLY


    1. Temporarily install the radiator assembly to the vehicle.

    2. w/ Air conditioning system:

      Attach the 2 guides and 2 claws to connect the cooler condenser assembly to the radiator assembly.

      Note


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

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

    3. B0068JDC01
      *a Claw

      Hook the claw of the radiator assembly as shown in the illustration.

    4. B0068MZN01

      Install the radiator assembly with the 4 bolts in the order shown in the illustration.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  4. CONNECT NO. 2 RADIATOR HOSE


    1. B0068LUC01
      *a Paint Mark
      *b Protrusion

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

      Note

      Connect the No. 2 radiator hose so that the paint mark on the No. 2 radiator hose is aligned with the protrusions of the radiator assembly as shown in the illustration.

  5. INSTALL FAN SHROUD


    1. Install the fan pulley to the engine water pump assembly.

    2. Place the fan shroud together with the fluid coupling assembly between the engine and radiator assembly.

      Note

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

    3. Temporarily install the fluid coupling assembly to the engine water pump assembly with the 4 nuts.

      Note

      Make sure to align the paint mark on the fluid coupling assembly and the paint mark on the stud bolt of the engine water pump assembly.

    4. Attach the 2 guides and 2 claws to install the fan shroud to the radiator assembly.

    5. Install the fan and generator V belt.

      Click here

    6. Tighten the 4 nuts holding the fan with fluid coupling assembly.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    7. Attach the 2 wire harness clamps.

  6. INSTALL RADIATOR RESERVOIR


    1. Install the radiator reservoir with the 2 bolts.

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

    2. Connect the water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

    3. Connect the No. 2 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

    4. Attach the clamp to connect the No. 2 water by-pass hose to the fan shroud.

  7. INSTALL OIL RESERVOIR BRACKET


    1. Temporarily install the oil reservoir bracket with the 3 bolts and tighten the 3 bolts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

  8. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. Attach the claw to connect the vane pump oil reservoir assembly to the oil reservoir bracket.

    2. Attach the clamp to connect the pressure feed tube assembly to the fan shroud.

  9. INSTALL NO. 1 RADIATOR HOSE


    1. B0068MCC01
      *a Paint Mark
      *b Protrusion

      Install the No. 1 radiator hose and slide the 2 hose clamps to secure the hose.

      Note

      Connect the No. 1 radiator hose so that the paint mark on the No. 1 radiator hose is aligned with the protrusions of the radiator assembly and water outlet as shown in the illustration.

  10. ADD ENGINE COOLANT

    Click here

  11. INSPECT FOR COOLANT LEAK

    Click here

  12. INSTALL NO. 1 RADIATOR AIR GUIDE


    1. Install the No. 1 radiator air guide with 4 new clips.

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

    Click here

  14. INSTALL RADIATOR SIDE DEFLECTOR