RADIATOR INSTALLATION


  1. INSTALL RADIATOR DRAIN COCK PLUG


    1. Install the radiator drain cock plug to the radiator assembly.

      Note

      Replace the O-ring if it is damaged.

  2. INSTALL RADIATOR TO SUPPORT SEAL


    1. A0119EEE01

      Wipe off any tape adhesive residue with cleaner.

    2. Remove the release paper from the support seal.

    3. Install the 5 new support seals to the radiator.

  3. INSTALL FAN SHROUD


    1. A0117TS

      Install the 2 pawl fittings and the fan shroud.

    2. Engage the 2 claws.

  4. INSTALL RADIATOR ASSEMBLY


    1. A011AJS

      Install the 2 cushions and 2 grommets.

    2. A0117ED

      Engage the 2 claws and install the radiator assembly together with the fan shroud onto the vehicle.

      Note

      Do not apply any excessive force to the cooler condenser assembly or piping when installing the radiator assembly.

    3. A0118XM

      Engage the 5 wire harness clamps and connect the hose, 2 connectors.

    4. A011BVT

      Engage the claw and install the piping clamp.

  5. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A011BK4

      Install the radiator upper support with the 5 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the horn connector.

  6. INSTALL RADIATOR SUPPORT UPPER ABSORBER

    A011BBL

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

  7. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY


    1. A01178A

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

  8. CONNECT NO. 2 RADIATOR HOSE


    1. A0118WFE01

      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.

  9. CONNECT NO. 1 RADIATOR HOSE


    1. A011B0UE01

      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.

  10. CONNECT NO. 4 WATER BY-PASS HOSE


    1. A0118B7E01

      Connect the water by-pass hose to the radiator assembly with the hose clamp.

      Note

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

  11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  12. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A011BX8

      Install the air cleaner filter element.

      Note

      Engage the air cleaner filter element protrusion with the air cleaner case groove.

  13. INSTALL AIR CLEANER CAP ASSEMBLY


    1. A0119FRE01

      Engage the 2 claws and 2 clamps and install the air cleaner cap.

    2. Connect the connector and 2 wire harness clamps.

      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp
    3. A0118S5E01

      Connect the air cleaner hose to the air cleaner cap.

      Tech Tips


      • The clamp should contact the air cleaner hose stopper.

      • Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.

  14. ADD ENGINE COOLANT (w/o Combustion Type Power Heater)


    1. Tighten the radiator drain cock plug.

    2. A011BIVE01
      Text in Illustration
      *1 Air Bleed Valve 1
      *2 Air Bleed Valve 2

      Loosen the air bleed valve 1 and the air bleed valve 2.

    3. Add TOYOTA Super Long Life Coolant (SLLC).

      Standard Capacity
      Item Capacity
      w/o Combustion Type Power Heater 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. A0118K8E01
      Text in Illustration
      *1 B Line

      Add coolant to the B line of the radiator reserve tank.

    5. 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.

    6. A011BIVE01
      Text in Illustration
      *1 Air Bleed Valve 1
      *2 Air Bleed Valve 2

      Tighten the air bleed valve 1 and the air bleed valve 2.

    7. Install the reserve tank cap sub-assembly.

    8. Start the engine and warm it up.

    9. 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.

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

    11. A0118K8E02
      Text in Illustration
      *1 FULL Line
      *2 LOW Line

      After the engine has 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.

  15. ADD ENGINE COOLANT (w/ Combustion Type Power Heater)


    1. Tighten the radiator drain cock plug.

    2. A011BIVE01
      Text in Illustration
      *1 Air Bleed Valve 1
      *2 Air Bleed Valve 2

      Loosen the air bleed valve 1 and the air bleed valve 2.

    3. Add TOYOTA Super Long Life Coolant (SLLC).

      Standard Capacity
      Item Capacity
      w/ Combustion Type Power Heater 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).

    4. A0118K8E01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the radiator reserve tank.

    5. 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.

    6. A011BIVE01
      Text in Illustration
      *1 Air Bleed Valve 1
      *2 Air Bleed Valve 2

      Tighten the air bleed valve 1 and the air bleed valve 2.

    7. Start the engine, maintain the speed at 3000 rpm for 10 seconds, and idle the engine for 10 seconds. Repeat the same procedure above 4 more times.

    8. Install the reserve tank cap sub-assembly.

    9. Loosen the air bleed valve 1 and the air bleed valve 2.

    10. Add 350 cc (21.3 cu in.) coolant.

    11. Tighten the air bleed valve 1 and the air bleed valve 2.

    12. Start the engine and warm it up.

    13. 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.

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

    15. A0118K8E02
      Text in Illustration
      *1 FULL Line
      *2 LOW Line

      After the engine has 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.

  16. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A011BFQE01
      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.

  17. INSTALL ENGINE UNDER COVER

    A011A8B

    1. Install the engine under cover assembly with the 4 bolts and the 4 clips.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  18. INSTALL FRONT BUMPER COVER


    1. Install the front bumper cover Click here.