RADIATOR INSTALLATION

INSTALL HOOD LOCK CONTROL CABLE COVER (w/ Cover)

1. Attach the guide to install the hood lock control cable cover.

INSTALL HOOD LOCK ASSEMBLY (for LHD)

1. Connect the hood lock control cable to the hood lock.

2. Install the hood lock with the 3 bolts.

   Torque:

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

INSTALL HOOD LOCK ASSEMBLY (for RHD)

1. Connect the hood lock control cable to the hood lock.

2. Install the hood lock with the 3 bolts.

   Torque:

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

INSTALL HOOD LOCK RELEASE LEVER PROTECTOR

1. Install the hood lock release lever protector with the 2 clips.

2. Attach the 2 clamps and connect the connector.

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

1. 

   Text in Illustration

   *1	Bump
   *2	Cutout
   *3	Protrusion

   Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.

   Torque:

   4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

   Note

   
   

   • Insert the protrusion on the throttle body side hose into the hole of the hose clamp.

   • Align the bump on the throttle body side with the cutout in the hose.

2. Connect the VSV hose to the air cleaner hose.

3. Connect the mass air flow meter connector and clamp to the air cleaner.

ADD ENGINE COOLANT

1. Tighten the 2 cylinder block drain cock plugs.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

2. Tighten the radiator drain cock plug.

3. Remove the reservoir tank cap and radiator cap.

4. 

   Text in Illustration

   *1

   B Line

   Add coolant through the radiator reservoir tank filler opening until the coolant reaches the "B" line and install the reservoir tank cap.

   Standard Capacity
   Radiator Core Thickness [mm] Specified Condition 16 9.4 liters (9.9 US qts, 8.3 Imp. qts) 27 9.9 liters (10.5 US qts, 8.7 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).

5. Add engine coolant to the coolant filler opening and install the radiator cap.

   Tech Tips

   Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

6. Put the engine in inspection mode Click here. [*1]

7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

   CAUTION:

   
   

   • Wear protective gloves.

   • Be careful as the radiator hoses are hot.

   • Keep your hands away from the radiator fans.

   Note

   
   

   • Immediately after starting the engine, if the radiator reservoir tank does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant.

   • Do not start the engine when there is no coolant in the radiator reservoir tank.

   • Make sure that the needle does not show an abnormally high temperature.

   • If there is not enough coolant, the engine may overheat.

   Tech Tips

   
   

   • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

   • The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

9. Check the coolant level in the radiator reservoir tank. [*4]

   Tech Tips

   
   

   • If the coolant level is below the "Low" line, add coolant through the radiator reservoir tank filler opening until the coolant reaches the "B" line and repeat steps [*1] through [*4].

   • If the coolant level is above the "FULL" line, drain coolant until the coolant level is between the "FULL" and "LOW" line.

INSPECT FOR COOLANT LEAK

1. Remove the reservoir tank cap.

2. Fill the radiator with coolant and 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 137 kPa (1.4 kgf/cm², 20 psi), and check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

INSTALL NO. 1 AIR CLEANER INLET

1. Install the No. 1 air cleaner inlet with the bolt.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

INSTALL ENGINE UNDER COVER

1. Install the engine under cover with the 13 screws and 3 clips.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

   Text in Illustration

   *1	Tip (Round Portion)

   Attach the 3 clips in the order shown in the illustration to install the V-bank cover.

   Note

   
   

   • Securely attach the clips.

   • If the clips are forcibly attached or struck with an object, they may be damaged.

   • Do not apply any oil to the tips (round portions).

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

Text in Illustration

*1	Approx. 10 m (32.8 ft.)
*2	Approx. 14 m (45.9 ft.)

Note

• 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.

1. Before adjusting the radar beam axis, prepare the vehicle as follows.

   
   

   1. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

   2. Check the tire pressure and adjust it if necessary Click here.

2. 

   Text in Illustration

   *1

   Level

   Check and adjust the vertical direction of the radar sensor.

   
   

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

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

   3. 

      Text in Illustration

      *1	Level
      *2	Air Bubble
      *3	Bolt A
      *a	FR
      *b	LH

      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 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°).

        Adjustment
        Adjustment Direction Adjustment Procedure Adjustment Angle Vertical adjustment Upward direction: Turn bolt A to negative (-) side For 1 complete turn of screwdriver, sensor moves about 0.12° Downward direction: Turn bolt A to positive (+) side

3. 

   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, a string with a sharp-pointed weight (plumb bob), and a 5 m (16.4 ft.) tape measure.

4. 

   Place the reflector.

   
   

   1. 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.

   2. 

      Text in Illustration

      *a	Adjust Center By Moving String To Right And Left
      *b	Extend String Through Front Center Mark

      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.

   3. Place the reflector (SST) at the marked position.

      Note

      Perform the operation as precisely as possible.

      

      Text in Illustration

      *a	Reflector (SST) Placement Point	*b	Millimeter Wave Radar Sensor Position
      *c	5 m (16.4 ft.)	*d	13.1 mm (0.516 in.)

5. Check the radar beam axis.

   
   

   1. When using the GTS:

      
      

      1. Connect the GTS to the DLC3.

      2. Turn the power switch on (IG).

      3. Turn the GTS on, and turn the cruise control main switch on.

      4. Select "Connect to Vehicle".

      5. Select each item on the display screen and proceed to the next screen.

      6. Under "System Selection Menu", select "Radar Cruise".

      7. Select "Utility".

      8. Select "Beam Axis Adjustment" and proceed to the next screen.

         Tech Tips

         A buzzer will sound for 1 second.

      9. Follow the GTS display, and continue with the adjustment.

         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.

   2. Check the following items on the radar cruise divergence data screen.

      Note

      While using the GTS beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the GTS data. In such a case, the deviation is displayed on the multi-information display in the combination meter.

      
      

      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).

6. Check and adjust the horizontal direction of the radar sensor.

   
   

   1. 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 bolt B until the divergence of the radar beam axis is 0°.

   2. 

      Text in Illustration

      *1

      Bolt B

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

      Adjustment
      Adjustment Direction Adjustment Procedure Adjustment Angle Horizontal adjustment Right direction: Turn bolt B to positive (+) side. For 1 complete turn of screwdriver, sensor moves about 0.07° Left direction: Turn bolt B to negative (-) side.

      Tech Tips

      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.

   3. Finish the beam axis adjustment.

   4. Disconnect the GTS from the DLC3.

7. Recheck and readjust the vertical direction of the radar sensor.

   
   
   1. 

      Text in Illustration

      *1

      Level

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

   2. 

      Text in Illustration

      *1	Level
      *2	Air Bubble
      *3	Bolt A
      *a	FR
      *b	LH

      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 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°).

        Adjustment
        Adjustment Direction Adjustment Procedure Adjustment Angle Vertical adjustment Upward direction: Turn bolt A to negative (-) side For 1 complete turn of screwdriver, sensor moves about 0.12° Downward direction: Turn bolt A to positive (+) side

INSTALL COOL AIR INTAKE DUCT SEAL

1. Install the cool air intake duct seal with the 7 clips.

INSTALL ENGINE ROOM SIDE COVER

1. Install the engine room side cover with the 4 clips.