RADIATOR INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


    1. A003SH1

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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    2. A003TSO

      Install the 2 lower radiator supports.

    3. Install the radiator assembly with the fan shroud.

      Note

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

    4. A003T4V

      Connect the 2 wire harness clamps and 2 connectors.

  2. INSTALL NO. 2 FAN SHROUD


    1. A003TEK

      Install the No. 2 fan shroud with the 2 bolts and 2 claws.

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

  3. CONNECT NO. 5 INVERTER COOLING HOSE


    1. A003RWR

      Connect the 3 clamps and No. 5 inverter cooling hose to the fan shroud.

  4. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A003RM1

      Connect the 4 clamps and No. 3 water by-pass hose.

  5. CONNECT WATER BY-PASS HOSE


    1. A003T61

      Connect the water by-pass hose.

  6. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A003U6G

      Install the hood lock support sub-assembly with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003S7S

      Connect the horn connector.

  7. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch)


    1. A003SHY

      Apply MP grease to the sliding areas of the lock.

    2. Install the hood lock assembly with the 3 bolts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    3. Connect the hood lock control cable.

  8. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch)


    1. A003TNW

      Apply MP grease to the sliding areas of the lock.

    2. Install the hood lock assembly with the 3 bolts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    3. Connect the hood lock control cable.

    4. Connect the connector.

  9. INSTALL RADIATOR SUPPORT RH


    1. Install the radiator support cushion to the radiator support RH.

    2. A003UVV

      Install the radiator support RH with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    3. Connect the No. 2 water by-pass hose clamp to the radiator support RH.

  10. INSTALL RADIATOR SUPPORT LH


    1. Install the radiator support cushion to the radiator support LH.

    2. A003S9K

      Install the radiator support LH with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  11. CONNECT NO. 2 RADIATOR HOSE


    1. A003UW3

      Connect the No. 2 radiator hose to the radiator assembly with the clamp.

  12. CONNECT NO. 1 RADIATOR HOSE


    1. A003UJF

      Connect the No. 1 radiator hose to the radiator assembly with the clamp.

  13. INSTALL NO. 1 INVERTER BRACKET


    1. A003USVE01

      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  { 138 kgf*cm, 10 ft.*lbf }

  14. 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. Install the hose to the 3 hose clamps.

    3. Install the air cleaner filter element.

  15. 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 No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp.

  16. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner cap sub-assembly with the 2 clamps.

    2. Tighten the hose clamp.

    3. Connect the mass air flow meter connector.

  17. INSTALL FRONT BUMPER ASSEMBLY


    1. Connect the 2 fog light connectors.

    2. w/ Headlight Cleaner System:


      1. Fill up washer jar with washer fluid Click here.

    3. A003S2L

      Engage the 6 claws and install the front bumper assembly.

    4. A003T9S

      Install the 4 bolts and 3 clips.

    5. A003TD1

      Install the 6 screws.

    6. A003T5J

      Install the clip.

      Tech Tips

      Use the same procedure for the RH side and LH side.

    7. A003U0CE01
      Text in Illustration
      *1 Correct
      *2 Incorrect

      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.

    8. Remove the protective tape.

  18. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Connect the hose to the air release valve. (w/ Air Release Valve)

    3. Loosen the air release valve. (w/ Air Release Valve)

    4. Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve. (w/ Air Release Valve)

    5. Disconnect the hose from the air release valve. (w/ Air Release Valve)

    6. A003TGQE01
      Text in Illustration
      *1 B Line

      Add TOYOTA Super Long Life Coolant (SLLC) to the B line on 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.

    7. 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.

    8. Put the engine in inspection mode Click here.

    9. Install the reservoir tank cap.

    10. 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 the 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.

    11. A003TGQE02
      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 lines.

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

  19. 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. A003T8A

      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 a radiator 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.

  20. INSTALL NO. 1 ENGINE UNDER COVER

  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  22. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  23. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  24. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  25. ADJUST FOG LIGHT AIMING

    Click here