RADIATOR REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. REMOVE FRONT BUMPER ASSEMBLY (for ALPHARD)

    Click here

  3. REMOVE FRONT BUMPER ASSEMBLY (for VELLFIRE)

    Click here

  4. REMOVE V-BANK COVER ASSEMBLY


    1. A01CCP4

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  5. REMOVE NO. 1 ENGINE UNDER COVER

  6. DRAIN AUTOMATIC TRANSAXLE FLUID


    1. Remove the 5 clips and rear engine under cover LH.

    2. A01CEJG

      Using a 6 mm socket hexagon wrench, remove the overflow plug and gasket from the automatic transaxle.

    3. A01CCOF

      Remove the refill plug and gasket from the automatic transaxle.

    4. A01CEFPE02

      Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle.

    5. Drain automatic transaxle fluid from the automatic transaxle.

    6. A01CEFPE02

      Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube to the automatic transaxle.

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    7. A01CEJG

      Using a 6 mm socket hexagon wrench, install a new gasket and the overflow plug to the automatic transaxle.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A01CCOF

      Install a new gasket and the refill plug to the automatic transaxle.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  7. 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 plugs and radiator drain cock plug while the engine and 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 regulations in your area.

    2. Remove the reserve tank cap.

    3. Loosen the 2 cylinder block drain cock plugs.

      A01CEIKE01

  8. REMOVE BATTERY


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

    2. A01CDEA

      Disconnect the 2 wire clamps.

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

    4. Remove the battery, battery insulator and battery tray.

  9. 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.

  10. 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.

  11. DISCONNECT NO. 3 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. w/ No. 2 Air Conditioning Tube:


      1. A01CFCB

        Remove the bolt and disconnect the No. 3 air conditioning tube and accessory assembly from the condenser.

    2. w/o No. 2 Air Conditioning Tube:


      1. A01CE6E

        Remove the bolt and disconnect the No. 3 air conditioning tube and accessory assembly from the condenser.

    3. Remove the O-ring from the No. 3 air conditioning tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  12. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A


    1. w/ No. 2 Air Conditioning Tube:


      1. A01CGAK

        Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser.

    2. w/o No. 2 Air Conditioning Tube:


      1. A01CETP

        Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser.

    3. Remove the O-ring from the cooler refrigerant liquid pipe A.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  13. REMOVE NO. 1 AIR CLEANER INLET


    1. A01CBFW

      Remove the bolt and No. 1 air cleaner inlet.

  14. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH (for ALPHARD)


    1. A01CDLA

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

  15. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH (for VELLFIRE)


    1. A01CAZN

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

  16. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH (for ALPHARD)


    1. A01CFHW

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

  17. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH (for VELLFIRE)


    1. A01CDLL

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

  18. REMOVE HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. A01CCAK

      Disconnect the 5 wire harness clamps.

    2. Disconnect the 4 connectors.

    3. A01CG3S

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

  19. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01CAP1

      Disconnect the hose clamp and No. 1 radiator hose.

  20. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01CBTY

      Disconnect the No. 2 radiator hose.

  21. DISCONNECT OIL COOLER HOSE


    1. A01CFZY

      Disconnect the 2 oil cooler hoses.

  22. DISCONNECT NO. 2 WATER BY-PASS HOSE


    1. A01CFMI

      Disconnect the No. 2 water by-pass hose.

  23. DISCONNECT NO. 1 WATER BY-PASS PIPE


    1. A01CCA8

      Disconnect the No. 3 water by-pass hose.

    2. A01CF7R

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

    3. A01CAYI

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

  24. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01CCLE

      Disconnect the 2 clamps and 2 cooling fan ECU connectors.

    2. A01CECY

      Disconnect the 6 wire harness clamps.

    3. A01CG81

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

    4. Remove the 2 radiator support cushions.

  25. REMOVE NO. 2 FAN SHROUD


    1. A01CDKW

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

  26. REMOVE COOLER CONDENSER ASSEMBLY


    1. A01CFTT

      Remove the cooler condenser assembly as shown in the illustration.

  27. REMOVE RADIATOR ASSEMBLY


    1. A01CEQA

      Disconnect the suction hose from the hose clamp.

    2. A01CBQS

      Remove the radiator with fan shroud and fan motors.

    3. Remove the 2 lower radiator supports.

    4. A01CFZJ

      w/o Air cooled oil cooler:


      1. Disconnect the 2 oil cooler hoses.

      2. Remove the 3 bolts and oil cooler pipe.

    5. A01CBIZ

      w/ Air cooled oil cooler:


      1. Disconnect the 2 oil cooler hoses.

      2. Remove the 3 bolts and oil cooler pipe.

    6. A01CBG6

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