RADIATOR INSTALLATION

INSTALL HOOD LOCK ASSEMBLY

1. Apply MP grease to the sliding areas of the lock.

   

2. Connect the hood lock control cable assembly.

3. Install the hood lock assembly with the 3 bolts.

   Torque:

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

4. w/ Engine Hood Courtesy Switch:

   1. Connect the connector.

INSTALL RADIATOR GRILLE SUB-ASSEMBLY

1. Engage the 8 claws to install the radiator grille sub-assembly.

   

   Text in Illustration

   *A

   for Standard

   *B

   for Sport Package

2. Install the 3 clips.

INSTALL INLET NO. 1 AIR CLEANER

1. Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.

   

2. Engage the pin to the radiator support.

INSTALL INLET NO. 2 AIR CLEANER

1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

2. Connect the 2 wire harness clamps and vacuum hose clamp.

INSTALL BATTERY

1. Install the battery and battery tray.

2. Install the battery clamp with the bolt and nut.

   Torque:

   Bolt

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

   Nut

   3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

3. Connect the positive (+) cable to the positive (+) battery terminal.

   Torque:

   6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Close the 2 cylinder block drain cock plugs.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

3. Loosen the air drain cock plug on the water inlet housing.

4. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

5. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Specified capacity
   9.1 liters (9.6 US qts, 8.0 lmp. qts)

   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).

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

7. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level is low, add coolant.

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

9. 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 coolant for several minutes.

      Tech Tips

      The thermostat open timing can be confirmed by squeezing the outlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

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

   3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:

      When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note

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

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

      • If there is not enough coolant, the engine may overheat or be seriously damaged.

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

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

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

INSPECT FOR COOLANT LEAK

1. 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*cm, 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.

INSTALL COOL AIR INTAKE DUCT SEAL

1. Install the cool air intake duct seal with the 7 clips.