RADIATOR INSTALLATION

INSTALL RADIATOR ASSEMBLY
1. Install the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Install the fan shroud to the radiator assembly.
3. Install the 2 lower radiator supports.
4. Install the radiator assembly with the fan shroud.
  
  Note
  
  For vehicles with the air conditioning system, do not apply any excessive force to the cooler condenser assembly or pipe when installing the radiator assembly.
INSTALL NO. 2 FAN SHROUD
1. Install the No. 2 fan shroud with the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the 6 water by-pass hose clamps to the No. 2 fan shroud.
3. Connect the water by-pass hose to the radiator assembly.
4. Connect the No. 1 water by-pass hose to the radiator assembly.
INSTALL AIR CLEANER CASE
1. Install the air cleaner case with the 3 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the No. 4 water by-pass hose to the air cleaner case with the 3 clamps.
3. Install the air cleaner filter element.
INSTALL INLET AIR CLEANER ASSEMBLY
1. Install the inlet air cleaner assembly with the 3 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the wire harness clamp to the inlet air cleaner assembly.
3. Connect the No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly with the 2 clamps and hose band.
2. Connect the air flow meter connector.
INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
1. Install the upper radiator support with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Install the 2 cushions to the radiator support RH and radiator support LH.
3. Install the radiator support RH and radiator support LH with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
4. Connect the 2 horn connectors.
5. Connect the 2 wire harness clamps and connector to the fan shroud and cooling fan motor.
6. Connect the connector to the No. 2 cooling fan motor.
7. Connect the hood lock connector and hood lock control cable wire.
8. Connect the 3 wire harness clamps.
9. Connect the water by-pass hose clamp to the radiator support RH.
INSTALL NO. 1 INVERTER BRACKET
1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  14 N*m { 140 kgf*cm, 10 ft.*lbf }
INSTALL MILLIMETER WAVE RADAR SENSOR BRACKET
1. w/o Dynamic Radar Cruise Control System:
  1. Install the millimeter wave radar sensor bracket with the 3 bolts.
    
    Torque:
    
    6.2 N*m { 63 kgf*cm, 55 in.*lbf }
    
    Note
    
    Tighten the bolts in the order shown in the illustration to install the millimeter wave radar sensor bracket.
2. w/ Dynamic Radar Cruise Control System:
  1. Install the millimeter wave radar sensor bracket with the bolt.
    
    Torque:
    
    6.2 N*m { 63 kgf*cm, 55 in.*lbf }
INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)
1. Tighten the 5 bolts on the millimeter wave radar sensor assembly.
  
  Torque:
  
  6.2 N*m { 63 kgf*cm, 55 in.*lbf }
  
  Tech Tips
  
  Tighten the bolts in the order indicated in the illustration.
2. Connect the connector.
INSTALL FRONT BUMPER ASSEMBLY
1. Connect the headlight cleaner hose. (w/ Headlight Cleaner System)
2. Connect each connector.
3. Install the front bumper assembly as shown in the illustration.
4. Engage the 3 claws to install the front bumper assembly.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
5. Engage the 2 guides and install the front spoiler cover. (w/ Front Spoiler)
6. Install the 2 clips and 2 screws. (w/ Front Spoiler)
7. Install the 7 clips.
8. Install the 2 bolts and 4 screws.
9. Install the screw.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
10. Install the pin hold clip.
  
  Note
  
  Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertical.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
CONNECT NO. 2 RADIATOR HOSE
1. Connect the No. 2 radiator hose to the radiator assembly with the clamp.
CONNECT NO. 1 RADIATOR HOSE
1. Connect the No. 1 radiator hose to the radiator assembly with the clamp.

ADD COOLANT (for Engine)

Tighten the radiator drain cock plug.
Remove the reservoir tank cap.

Text in Illustration
*1	B Line

Add coolant to B line of the reservoir tank.

Standard Capacity

Item

Capacity

Engine coolant

w/ Exhaust Heat Recirculation System:

7.2 liters (7.6 US qts, 6.3 lmp. qts)

w/o Exhaust Heat Recirculation System:

6.5 liters (6.8 US qts, 5.7 lmp. 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.

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.
Install the reservoir tank cap.
Put the engine in inspection mode Click here.
Bleed air from the cooling system.
Note
- Before starting the engine, turn the A/C switch off.
- Adjust the heater control to the maximum hot setting.
- Adjust the blower speed to low setting.
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. 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.
Text in Illustration

*1 Full Line

*2 Low Line

After the engine has cooled down, check that the coolant level is between full and low.

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

INSPECT FOR COOLANT LEAK (for Engine)
CAUTION:

Do not remove the reservoir tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Note

Before performing each inspection, turn the A/C switch off.
1. Remove the reservoir tank cap.
2. Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.
3. Put the engine in inspection mode Click here.
4. Warm up the engine.
5. Using the reservoir cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm², 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
6. Remove the radiator cap tester.
7. Install the reservoir tank cap.
INSTALL ENGINE UNDER COVER
INSTALL FRONT SPOILER COVER (w/ Front Spoiler)
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL REAR NO. 3 FLOOR BOARD
1. Engage the 2 guides to install the rear No. 3 floor board.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box.
INSTALL REAR NO. 2 FLOOR BOARD
1. Engage the 3 guides <A>.
2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.
INSTALL RADIATOR SUPPORT OPENING COVER
1. Engage the 2 claws and install the radiator support opening cover.
2. Install the 3 clips.
ADD WINDSHIELD WASHER FLUID (w/ Headlight Cleaner System)
1. Add washer fluid to the washer jar.
PREPARATION VEHICLE FOR FOG LIGHT AIM ADJUSTMENT
1. Prepare the vehicle:
  - Ensure there is no damage or deformation to the body around the fog lights.
  - Fill the fuel tank.
  - Make sure that the oil is filled to the specified level.
  - Make sure that the coolant is filled to the specified level.
  - Inflate the tires to the appropriate pressure.
  - Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions (except Taiwan).
  - Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are also removed (for Taiwan).
  - Sit a person of average weight (75 kg, 165 lb) in the driver's seat (except Taiwan).
  - Sit a person of average weight (55 kg, 121 lb) in the driver's seat (for Taiwan).
PREPARATION FOR FOG LIGHT AIMING
1. Prepare the vehicle (except Taiwan):
  - Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.
  - Place the vehicle at a 90° angle to the wall.
  - Create a 25 m (82 ft.) distance between the vehicle (fog light bulb center) and the wall.
  - Make sure that the vehicle is on a level surface.
  - Position the front wheels straight ahead.
  - Bounce the vehicle up and down to settle the suspension.
    
    Note
    
    A distance of 25 m (82 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)
2. Prepare the vehicle (for Taiwan):
  - Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.
  - Place the vehicle at a 90° angle to the wall.
  - Create a 10 m (32.8 ft.) distance between the vehicle (fog light bulb center) and the wall.
  - Make sure that the vehicle is on a level surface.
  - Position the front wheels straight ahead.
  - Bounce the vehicle up and down to settle the suspension.
    
    Note
    
    A distance of 10 m (32.8 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)
3. Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.
4. Draw a vertical line down the center of the screen (V line).
5. Set the screen as shown in the illustration (except Taiwan).
  Tech Tips
  
  Stand the screen perpendicular to the ground.
  
  Align the V line on the screen with the center of the vehicle.
6. Set the screen as shown in the illustration (for Taiwan).
  Tech Tips
  
  Stand the screen perpendicular to the ground.
  
  Align the V line on the screen with the center of the vehicle.
7. Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.
  
  Tech Tips
  
  Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.
  1. H Line (Fog light height):
    
    Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights.
  2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights):
    
    Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the fog light bulbs).
INSPECT FOG LIGHT AIMING
1. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection.
  
  Note
  
  Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat.
2. Start the engine.
3. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration (except Taiwan).
  Tech Tips
  
  If the alignment distance is 25 m (82 ft.):
  
  The upper edge of the hot zone for the fog light should be 502 mm (1.65 ft.) below the H line.
  
  If the alignment distance is 3 m (9.84 ft.):
  
  The upper edge of the hot zone for the fog light should be 60 mm (2.36 in.) below the H line.
4. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration (for Taiwan).
  Tech Tips
  
  If the alignment distance is 10 m (32.8 ft.):
  
  The upper edge of the hot zone for the fog light should be 201 mm (7.91 in.) below the H line.
  
  If the alignment distance is 3 m (9.84 ft.):
  
  The upper edge of the hot zone for the fog light should be 60 mm (2.36 in.) below the H line.
ADJUST FOG LIGHT AIMING (w/ Fog Light)
1. Text in Illustration
  
  *1 Aiming Screw
  
  Adjust the aim vertically:
  
  Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.
  
  Note
  
  The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.
  
  Tech Tips
  
  If it is not possible to correctly adjust fog light aim, check bulb, fog light unit and fog light unit reflector installation.

Text in Illustration
*1	Full Line
*2	Low Line

Text in Illustration
*1	Aiming Screw

ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

Text in Illustration
*1	Approx. 10 m
*2	Approx. 14 m

CAUTION:

Exposure to radio frequency emissions is hazardous to your health. It is hazardous to your health to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

Note

This device complies with FCC radio frequency emission regulations.
Perform measurements on a level surface.
Make sure that no large pieces of metal are within a 10 m (32.8 ft.) x 14 m (45.9 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.

Before adjusting the radar beam axis, prepare the vehicle as follows.
1. Check the tire pressure and adjust it if necessary.
2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

Text in Illustration
*1	Level

Check and adjust the vertical direction of the radar sensor.

Remove dust, oil and foreign matter from the radar sensor's level rack.
Set a level on the radar sensor's level rack.

Text in Illustration
*1	FR
*2	LH
*3	Level
*4	Air Bubble
*5	Bolt A

Check that the level's air bubble is within the red frame.

OK
Level's air bubble is within the red frame.

If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the air bubble is within the red frame.

Tech Tips

The adjustable range within the level's red frame is +/-0.2°.

The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Upward direction: Turn bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
Vertical adjustment	Downward direction: Turn bolt A to positive (+) side

Text in Illustration

*1 Millimeter Wave Radar Sensor

Adjust the reflector height.
1. Adjust the reflector so that the center of SST reflector is the same height as the millimeter wave radar sensor.
  
  SST
  
  09870-60000 ( 09870-60010 )
  
  09870-60040
  
  Tech Tips
  
  Prepare a 10 m (32.8 ft.) string, string with a sharp-pointed weight (plumb bob), and 5 m (16.4 ft.) tape measure.

Text in Illustration
*1	Millimeter Wave Radar Sensor

Place the reflector.

Hang the string (with weight) from the center of the vehicle's rear emblem. Mark the vehicle's rear center point on the ground. Repeat for the front of the vehicle.
Set one end of the 10 m (32.8 ft.) string on the vehicle's rear center point. Run the string over the vehicle's front center point to a position 5 m (16.4 ft.) beyond the vehicle's front center point, as shown in the illustration. Mark the 5 m (16.4 ft.) position.

Using a tape measure, measure 15.7 mm (0.618 in.) to the right of the 5 m (16.4 ft.) position. Place the reflector at that position.

Note

Perform the operation as precisely as possible.

Text in Illustration
*1	Reflector Placement Point	*2	Millimeter Wave Radar Sensor Position

Check the radar beam axis.

When using the intelligent tester:
1. Connect the intelligent tester to the DLC3.
2. Turn the power switch on (IG).
3. Turn the intelligent tester on, and turn the cruise control main switch on.
4. Select "Auto" from the intelligent tester display screen.
5. Select "Radar Cruise" from the display screen.
6. Select "Utility" from the display screen.
7. Select "Beam Axis Adjustment" from the display screen.
8. Follow the tester display, and select "Next".
  
  CAUTION:
  
  Do not come within 20 cm (7.87 in.) of the radar sensor.
  Note
  - Turn the cruise control main switch on before pressing "Next".
  - Make sure there is at least 20 cm (7.87 in.) between the radar sensor and any nearby individuals.
9. Check the following items on the laser cruise divergence data screen.
  
  Note
  
  While using the intelligent tester's beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the intelligent tester's data. In such a case, the deviation is displayed on the combination meter's multi-information display.
  1. Confirm that the distance value is approximately 5 m (16.4 ft.).
    Tech Tips
    - A value between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.) should be indicated.
    - If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).
  2. Confirm that the left/right side value is between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.).
    
    Tech Tips
    
    If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).

Check and adjust the horizontal direction of the radar sensor.

Check that the divergence of the radar beam axis is 0°.

Standard

0° (Both right and left)

If the axis is not as specified, use a screwdriver to adjust the bolt B until the divergence of the radar beam axis is 0°.

Standard
0° (Both right and left)

Text in Illustration
*1	Bolt B

Based on the measured divergence of the beam axis, turn and adjust the bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Horizontal adjustment	Right direction: Turn bolt B to positive (+) side.	For every 2.5 rotations of adjustment bolt, sensor moves about 1°
Horizontal adjustment	Left direction: Turn bolt B to negative (-) side.

Tech Tips

If "LEFT SIDE: 1.0°" is displayed, the divergence is 1.0° in the left direction. Turn the bolt B approximately 2.5 turns to the negative (-) side.
If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.

Select "Next". The driving learning value is automatically reset.

Tech Tips

A buzzer will sound for 10 seconds or more.
Disconnect the intelligent tester from the DLC3.

Recheck and readjust the vertical direction of the radar sensor.

Text in Illustration

*1 Level

Set a level on the radar sensor's level rack.

Text in Illustration
*1	FR
*2	LH
*3	Level
*4	Air Bubble
*5	Bolt A

Check that the level's air bubble is within the red frame.

OK
Level's air bubble is within the red frame.

If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the level's air bubble is within the red frame.

Tech Tips

The adjustable range within the red frame is +/-0.2°.

The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Upward direction: Turn bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
Vertical adjustment	Downward direction: Turn bolt A to positive (+) side