COOLING FAN MOTOR INSTALLATION

INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

1. Install the upper radiator support with the 5 bolts.

   Torque:

   13 N*m  { 127 kgf*cm, 9 ft.*lbf }

2. Connect the wire harness clamp.

3. Engage the 2 clamps and install the hood lock control cable.

INSTALL RADIATOR LOWER NO. 1 AIR DEFLECTOR

1. Insert the 2 guides and install the radiator air deflector.

2. Install the 2 clips.

INSTALL HIGH PITCHED HORN ASSEMBLY

1. Install the horn with the bolt.

   Torque:

   20 N*m  { 199 kgf*cm, 14 ft.*lbf }

2. Connect the horn connector.

CONNECT NO. 3 RADIATOR HOSE

1. 

   Text in Illustration

   *1	White Paint Mark
   *a	View A
   *b	Upper Side
   *c	Projection On Radiator

   Connect the radiator hose to the radiator assembly with the hose clamp.

   Note

   Perform the installation with the hose clip and mark at the correct angle.

CONNECT RADIATOR RESERVOIR TANK HOSE

1. 

   Text in Illustration

   *a	View A
   *b	Upper Side
   *c	Front Side

   Connect the reservoir tank hose to the water filler with the hose clamp.

   Note

   Perform the installation with the hose clip at the correct angle.

2. Engage the hose clamp.

INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

1. Install the air cleaner filter element.

INSTALL AIR CLEANER AND HOSE

1. 

   Text in Illustration

   *1	Clamp
   *2	Guide

   Align the 2 hinges with the guides on the case and engage them in the grooves.

2. Install the air cleaner and hose with the 2 clamps.

3. 

   Text in Illustration

   *1	Recession
   *2	Protrusion
   *a	View A
   *b	Upper Side

   Connect the air cleaner hose with the hose clamp as shown in the illustration.

   Torque:

   3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

   Note

   
   

   • The clamp should contact the air cleaner hose stopper.

   
   

   • Perform the installation with the hose clip at the correct angle.

4. Connect the ventilation hose.

5. Install the mass air flow meter connector and the wire harness clamp.

INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

1. Engage the 2 guides and install the front bumper reinforcement

2. Tighten the 8 bolts.

   Torque:

   40 N*m  { 408 kgf*cm, 30 ft.*lbf }

3. 

   Engage the 5 clamps.

INSTALL WINDSHIELD WASHER JAR ASSEMBLY

1. Connect the connectors.

2. Connect the washer hose.

3. Engage the guide and install the windshield washer jar.

4. Engage the claw.

5. Tighten the 2 bolts.

   Torque:

   5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

INSTALL RADIATOR SUPPORT EXTENSION LH

1. Engage the 2 claws and install the radiator support extension.

INSTALL RADIATOR SUPPORT EXTENSION RH

INSTALL NO. 2 RADIATOR SIDE AIR SEAL

1. Engage the 2 claws and install the radiator side air seal.

INSTALL NO. 1 RADIATOR SIDE AIR SEAL

INSTALL FRONT BUMPER ENERGY ABSORBER

1. Engage the 2 guide and install the front bumper energy absorber.

INSTALL UPPER RADIATOR SUPPORT ABSORBER

1. Engage the 7 claws and install the radiator support upper absorber.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug.

2. 

   Text in Illustration

   *1	Air Bleed Valve

   Loosen the air bleed valve.

3. Remove the water filler cap sub-assembly.

4. 

   Text in Illustration

   *a	Filler Tube End
   *b	Coolant Level

   Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC) from the water filler (Coolant level should be within 20 mm (0.787 in.) from the filler tube end).

   Standard Capacity
   Item Capacity M/T 4.7 liters (5.0 US qts, 4.1 Imp. qts) CVT 4.9 liters (5.2 US qts, 4.3 Imp. qts)

   Note

   Never use water as a substitute for engine coolant.

   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).

5. Remove the reserve tank cap.

   If the coolant level is low, add coolant.

6. 

   Text in Illustration

   *a

   FULL Line

   Fill the radiator reserve tank with coolant to the FULL line.

7. 

   Text in Illustration

   *1	Air Bleed Valve

   Tighten the air bleed valve.

8. Install the water filler cap sub-assembly and reserve tank cap.

9. Start the engine and warm it up.

10. Bleed air from the cooling system.

    Tech Tips

    
    

    • Before starting the engine, turn the A/C switch off.

    • Adjust the air conditioning temperature setting to MAX (HOT).

    • Adjust the air conditioning blower setting to LO.

    
    

    1. Run the engine intermittently for 7 minutes or more (5 seconds running at 3000 rpm and 45 seconds idling, repeat several times).

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

12. 

    Text in Illustration

    *a	FULL Line
    *b	LOW Line

    After the engine is cooled down, check that the coolant level is between the FULL and LOW lines.

    If the coolant level is low, add coolant to the reservoir tank FULL line.

INSPECT FOR COOLANT LEAK

1. 

   Text in Illustration

   *1	Radiator Cap Tester

   Fill the radiator assembly with engine coolant, and attach a radiator cap tester.

2. Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.