RADIATOR INSTALLATION


  1. INSTALL FAN SHROUD


    1. A00DQTP

      Install the fan shroud to the radiator with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  2. INSTALL NO. 3 WATER BY-PASS HOSE


    1. A00DTFRE01

      Align the matchmarks as shown in the illustration and install the No. 3 water by-pass hose to the radiator.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  3. INSTALL OIL COOLER PIPE (for Automatic Transaxle)


    1. A00DRC7

      Install the oil cooler pipe with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    2. A00DR4V

      Connect the 2 oil cooler hoses.

  4. INSTALL RADIATOR ASSEMBLY

    A00DRC8

    1. Install the 2 lower radiator supports.

    2. Install the radiator together with the fan shroud.

    3. A00DSUL

      Connect the cooling fan ECU connector and wire harness clamp.

  5. CONNECT OIL COOLER HOSE (for Automatic Transaxle)


    1. A00DQW5

      Connect the 2 oil cooler hoses to the oil cooler pipe.

  6. CONNECT NO. 2 RADIATOR HOSE


    1. A00DSUTE01

      Align the matchmarks as shown in the illustration and connect the No. 2 radiator hose to the radiator with the clamp.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  7. CONNECT NO. 3 RADIATOR HOSE


    1. A00DSTOE01

      Align the matchmarks as shown in the illustration and connect the No. 3 radiator hose to the radiator with the clamp.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  8. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A00DQ3ME01

      Align the matchmarks as shown in the illustration and connect the No. 3 water by-pass hose to the No. 2 water by-pass hose.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  9. CONNECT NO. 1 WATER BY-PASS HOSE


    1. A00DUW1E01

      Align the matchmarks as shown in the illustration and connect the No. 1 water by-pass hose to the radiator with the clamp.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  10. INSTALL AMBIENT TEMPERATURE SENSOR (for Automatic Air Conditioning System)

    A005V6U

    1. Attach the claw to install the cooler bracket.

    2. A005TU3

      Attach the clamp to install the sensor.

    3. Connect the connector.

  11. INSTALL CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)

    A00DTJ8

    1. Install the condenser assembly with receiver as shown in the illustration.

      Tech Tips

      If the condenser is replaced with a new one, add compressor oil to the new condenser.

      Capacity
      40 cc (1.4 fl.oz)
      Compressor oil
      ND-OIL 8 or equivalent

  12. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

    4. A00DRY0

      Install the suction pipe sub-assembly to the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  13. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

    4. A00DSJH

      Install the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. INSTALL NO. 2 FAN SHROUD


    1. A00DQXS

      Attach the 2 claws and install the No. 2 fan shroud to the radiator with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    2. A00DRGX

      for Manual Transaxle:

      Attach the No. 3 water by-pass hose clamp.

    3. A00DS9C

      for Automatic Transaxle:

      Attach the 2 No. 3 water by-pass hose clamps.

  15. INSTALL FAN SHROUD CUSHION


    1. A00DUZS

      Install the 2 cushions.

  16. INSTALL UPPER RADIATOR SUPPORT


    1. A00DQVP

      Install the upper radiator support with the 5 bolts.

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

    2. Attach the 2 clamps to connect the No. 2 water by-pass hose.

    3. Connect the 2 horn connectors.

  17. INSTALL HOOD LOCK ASSEMBLY


    1. A003ARV

      Apply MP grease to the sliding areas of the lock.

    2. A003BY3E01

      Connect the hood lock control cable.

    3. Install the 3 bolts.

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

    4. w/ Engine Hood Courtesy Switch:

      Connect the connector.

  18. INSTALL BATTERY TRAY

  19. INSTALL BATTERY

  20. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A00OLE3E01

      Install the battery clamp with the bolt and nut.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    2. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  21. CONNECT NO. 1 WATER HOSE CLAMP BRACKET

    A00DSJI

    1. Connect the hose clamp bracket with the 2 bolts.

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

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  23. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug.

    2. A00DQVX

      Add TOYOTA Super Long Life Coolant (SLLC) through the radiator reservoir filler opening until the coolant reaches the B line.

      Standard Capacity
      Item Specified Condition
      for Manual Transaxle 6.3 liters (6.7 US qts, 5.5 Imp. qts)
      for Automatic Transaxle 6.2 liters (6.6 US qts, 5.4 Imp. qts)

      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).

      Note

      Never use water as a substitute for engine coolant.

    3. 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.

    4. Install the cap and warm up the engine sufficiently.

    5. 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

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. After the engine has warmed up, repeat the following procedure for at least 7 minutes: run the engine at 3000 rpm for 5 seconds, and then at idle speed for 45 seconds (repeat this procedure at least 8 times).

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. A00DQVX

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

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

  24. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the reserve tank cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. A005TAG

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

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

  25. CHARGE REFRIGERANT (w/ Air Conditioning System)

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      440 +/-30 g (15.5 +/-1.1 oz)
      A00DTEOE26

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 200 g (7.05 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  26. WARM UP ENGINE (w/ Air Conditioning System)


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  27. CHECK FOR REFRIGERANT GAS LEAK (w/ Air Conditioning System)


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation observing the following instructions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A00DTQYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

  28. INSTALL NO. 1 ENGINE UNDER COVER


    1. A00ON3U

      Install the under cover with the 10 clips.

  29. INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A00OL2M

      Install the under cover with the 3 clips.

  30. INSTALL FRONT BUMPER ABSORBER LOWER


    1. A00OI9A

      Install the front lower bumper absorber with the 3 screws and 8 bolts.

    2. A00OL3A

      Install the 4 screws and 2 bolts.

  31. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas A to H are within the standard range.

      A005UW1E01
      Standard
      Area Specified Condition Area Specified Condition
      A 3.2 to 6.2 mm (0.126 to 0.244 in.) E 4.0 to 7.0 mm (0.158 to 0.276 in.)
      B -0.5 to 2.5 mm (-0.0197 to 0.0984 in.) F -0.9 to 2.1 mm (-0.0354 to 0.0827 in.)
      C 2.7 to 5.7 mm (0.106 to 0.224 in.) G 3.7 to 6.7 mm (0.146 to 0.264 in.)
      D -0.5 to 2.5 mm (-0.0197 to 0.0984 in.) H -0.5 to 2.0 mm (-0.0197 to 0.0787 in.)

  32. ADJUST HOOD SUB-ASSEMBLY


    1. A003EFE

      Adjust the hood position.


      1. Loosen the 4 hinge bolts on the hood.

      2. Move the hood and adjust the clearance between the hood and front fender.

      3. Tighten the 4 hinge bolts on the hood after the adjustment.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003DNO

      Adjust the cushion rubber so that the hood and fender are aligned.

      Tech Tips

      Raise or lower the front end of the hood by turning the cushion rubber.

    3. Adjust the hood lock.


      1. A003D6O

        Loosen the 3 bolts.

      2. Adjust the hood lock position so that the striker can enter it smoothly.

      3. Tighten the 3 bolts after the adjustment.

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

  33. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A00DRS1

      Install the radiator support opening cover with the 8 clips.

  34. INSTALL ENGINE ROOM SIDE COVER


    1. A00DRIG

      Install the engine room side cover with the clip.