RADIATOR REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE FRONT BUMPER ASSEMBLY

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER

  4. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug and drain the coolant.

      CAUTION:

      Do not remove the reserve tank cap, cylinder block drain cock plug and radiator drain cock plug while the engine or radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    2. Remove the reserve tank cap.

    3. Loosen the cylinder block drain cock plug. (except TMC Made)

      A01CC25E01
      Text in Illustration
      *1 Radiator Reserve Tank *2 Reserve Tank Cap
      *3 Cylinder Block Drain Cock Plug (except TMC Made) *4 Cylinder Block Drain Cock Plug (for TMC Made w/o Oil Cooler)
      *5 Water Drain Cock Plug (for TMC Made w/ Oil Cooler) *6 Radiator Drain Cock Plug

    4. Loosen the cylinder block drain cock plug. (for TMC Made w/o Oil Cooler)

    5. Loosen the water drain cock plug. (for TMC Made w/ Oil Cooler)

  5. REMOVE NO. 1 AIR CLEANER INLET


    1. A01CBFW

      Remove the bolt and No. 1 air cleaner inlet.

  6. REMOVE BATTERY


    1. Disconnect the positive (+) cable from the positive (+) battery terminal.

    2. A01CDEA

      Disconnect the 2 wire clamps.

    3. Loosen the nut, and remove the bolt and battery clamp.

    4. Remove the battery and battery insulator.

  7. REMOVE BATTERY TRAY


    1. Remove the battery tray.

  8. REMOVE HOOD LOCK ASSEMBLY (for LHD)


    1. w/o Engine Hood Courtesy Switch:


      1. A01CBXD

        Remove the 3 bolts.

      2. A01CF0U

        Disconnect the hood lock control cable and remove the hood lock assembly.

    2. w/ Engine Hood Courtesy Switch:


      1. A01CDRQ

        Disconnect the connector.

      2. A01CEIJ

        Remove the 3 bolts.

      3. A01CEXC

        Disconnect the hood lock control cable and remove the hood lock assembly.

  9. REMOVE HOOD LOCK ASSEMBLY (for RHD)


    1. for ALPHARD:


      1. A01CF8O

        Remove the 3 bolts.

      2. A01CCXZ

        Disconnect the hood lock control cable and remove the hood lock assembly.

    2. for VELLFIRE:


      1. A01CATX

        Remove the 3 bolts.

      2. A01CAW6

        Disconnect the hood lock control cable and remove the hood lock assembly.

  10. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH


    1. A01CDLA

      Remove the 2 clips and No. 2 front bumper side seal LH.

  11. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH


    1. A01CFHW

      Remove the 2 clips and No. 2 front bumper side seal RH.

  12. REMOVE HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. w/ smog ventilation sensor:


      1. A01CCAK

        Disconnect the 5 wire harness clamps.

      2. Disconnect the 4 connectors.

    2. w/o smog ventilation sensor:


      1. A01CGG7

        Disconnect the 5 wire harness clamps.

      2. Disconnect the 3 connectors.

    3. A01CG3S

      Remove the 2 bolts and hood lock support brace sub-assembly.

  13. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01CAP1

      Disconnect the hose clamp and No. 1 radiator hose.

  14. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01CBTY

      Disconnect the No. 2 radiator hose.

  15. DISCONNECT OIL COOLER HOSE (w/ Oil Cooler)


    1. A01CFZY

      Disconnect the 2 oil cooler hoses.

  16. DISCONNECT NO. 2 WATER BY-PASS HOSE


    1. A01CFUY

      Disconnect the No. 2 water by-pass hose.

  17. DISCONNECT NO. 1 WATER BY-PASS PIPE


    1. A01CCYH

      Disconnect the No. 3 water by-pass hose.

    2. A01CF7R

      Remove the bolt and No. 1 cooler refrigerant suction hose.

    3. A01CDFI

      Remove the 2 bolts and No. 1 water by-pass pipe.

  18. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01CECY

      Disconnect the 6 wire harness clamps.

    2. A01CG8I

      Disconnect the clamp and 2 connectors.

    3. A01CG5M

      Remove the 4 bolts and upper radiator support sub-assembly.

    4. Remove the 2 radiator support cushions.

  19. REMOVE NO. 2 FAN SHROUD


    1. A01CBTP

      Remove the 2 bolts, 2 claws and No. 2 fan shroud.

  20. REMOVE RADIATOR ASSEMBLY


    1. A01CBQS

      Remove the radiator with fan shroud and fan motors.

      Note

      Do not apply any excessive force to the cooler condenser assembly or pipe when removing the radiator assembly.

    2. Remove the 2 lower radiator supports.

    3. A01CFZJ

      w/ Oil Cooler:


      1. Disconnect the 2 oil cooler hoses.

      2. Remove the 3 bolts and oil cooler pipe.

    4. A01CFKC

      Remove the 2 bolts and fan shroud with fan motors from the radiator assembly.