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

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

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

   Tech Tips

   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	Front Side

   Connect the radiator reservoir tank hose to the radiator reservoir with the hose clamp.

   Tech Tips

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

2. Engage the hose clamp.

INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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

2. Install the air cleaner cap with the 2 clamps.

3. 

   Text in Illustration

   *a	View A
   *b	Upper Side
   *c	Front Side
   *d	Recession
   *e	Protrusion

   Connect the air cleaner hose as shown in the illustration.

   Tech Tips

   The clamp should contact the air cleaner hose stopper.

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 (w/ Water Inlet Drain Cock Plug)

ADD ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)

1. Tighten the radiator drain cock plug.

2. Remove the water filler cap sub-assembly.

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

   Standard Capacity
   Item Capacity for Manual Transaxle 4.3 liters (4.5 US qts, 3.8 Imp. qts) for CVT 4.5 liters (4.8 US qts, 4.0 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).

4. 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.

5. 

   Text in Illustration

   *a

   FULL Line

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

6. Install the water filler cap sub-assembly.

7. Start the engine and warm it up.

8. Bleed air from the cooling system.

   Note

   
   

   • 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. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      Tech Tips

      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:

      When squeezing the radiator hoses:
      

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fan.

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

10. Remove the water filler cap sub-assembly and check the coolant level.

    If the coolant level is below the LOW line, repeat all of the procedures above.

11. 

    Text in Illustration

    *a	FULL Line
    *b	LOW Line

    When the coolant level stops going 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.