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RADIATOR INSTALLATION

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  1. Click here

    INSTALL FAN SHROUD


    1. A01IQQWE02

      Insert the fan shroud hooks into the radiator holes and install the fan shroud with the 2 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf
      Table 1. Text in Illustration
      *A for Manual Transaxle
      *B for Automatic Transaxle
  2. Click here

    INSTALL INTERCOOLER ASSEMBLY


    1. Install the intercooler assembly with the 4 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf

    2. Connect the No. 1 vacuum transmitting hose to the intercooler assembly, and slide the clamp to secure it.

  3. Click here

    INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the lower radiator support RH with the 2 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf

    2. Attach the clamp to the vacuum transmitting pipe, and then install the lower radiator support LH with the 2 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf
  4. Click here

    INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Attach the clamp to the lower radiator support.

    2. Install the No. 1 vacuum transmitting pipe with the 3 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf
  5. Click here

    INSTALL OIL COOLER HOSE TUBE SUB-ASSEMBLY (for Automatic Transaxle)


    1. A01IUF6E01

      Connect the 2 hoses of the oil cooler hose tube to the radiator and slide the 2 clips.

      Table 2. Text in Illustration
      *1 Paint Mark
      *a Top
      *b RH Side
      *c Front Side
      *d 2 to 7 mm (0.0787 to 0.276 in.)
      Tip:

      • Position the clips and align the paint marks as illustrated.

      • Position the clips so that the distance from the end of the hose is 2 to 7 mm (0.0787 to 0.276 in.).

    2. Attach the 3 clamps and install the oil cooler hose tube with the bolt.

      5.5 N*m 56 kgf*cm 49 in.*lbf
  6. Click here

    INSTALL NO. 2 AIR TUBE


    1. Install the No. 2 air tube with the bolt.

      31 N*m 316 kgf*cm 23 ft.*lbf
      Note:

      Before installation, remove any oil residue from the inside of the pipe and hose.

    2. A01INBYE03

      Tighten the hose clamp.

      6.5 N*m 66 kgf*cm 58 in.*lbf
      Table 3. Text in Illustration
      *a 0 to 2 mm (0 to 0.0787 in.)
      Tip:

      Position the tube end so that the distance from the intercooler pipe is 0 to 2 mm (0 to 0.0787 in.).

    3. Connect the air temperature sensor connector.

  7. Click here

    INSTALL NO. 2 RADIATOR HOSE


    1. A01IRFME02

      Install the No. 2 radiator hose and slide the clamp to secure it.

      Tip:

      Position the clamp as illustrated.

      Table 4. Text in Illustration
      *1 Matchmark
      *a Top
      *b RH Side
  8. Click here

    INSTALL RADIATOR ASSEMBLY


    1. Install the 2 radiator lower support cushions.

    2. A01ITC1

      Insert the radiator with intercooler while holding it at an angle to install it as shown in the illustration.

      Note:

      w/ Air Conditioning System:

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

    3. for Automatic Transaxle:

      Connect the 2 oil cooler hoses and slide the 2 clips.

    4. Connect the No. 2 vacuum transmitting hose.

  9. Click here

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


    1. A01IPIA

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

      Tip:

      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-8 or equivalent
  10. Click here

    INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. Install the radiator support with the 4 bolts.

      13 N*m 127 kgf*cm 9 ft.*lbf
  11. Click here

    INSTALL HOOD LOCK ASSEMBLY


    1. A01INS6E01

      Apply MP grease to the sliding areas of the lock.

      Table 5. Text in Illustration
      *1 MP grease

    2. for LHD:


      1. A01IO2N

        Connect the hood lock control cable.

      2. A01IS1Z

        Install the hood lock with the 3 bolts.

        7.5 N*m 76 kgf*cm 66 in.*lbf

    3. for RHD:


      1. A01IQR4

        Connect the hood lock control cable.

      2. A01ITHB

        Connect the connector.

      3. Install the hood lock with the 3 bolts.

        7.5 N*m 76 kgf*cm 66 in.*lbf
  12. Click here

    INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the 2 upper radiator supports with the 4 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf

    2. Install the 2 radiator support cushions.

  13. Click here

    INSTALL UPPER RADIATOR SUPPORT (for Manual Transaxle)


    1. Install the 2 upper radiator supports with the 2 bolts.

      19 N*m 194 kgf*cm 14 ft.*lbf
  14. Click here

    INSTALL UPPER RADIATOR SUPPORT (for Automatic Transaxle)


    1. Install the 2 upper radiator supports with the 2 bolts.

      19 N*m 194 kgf*cm 14 in.*lbf
  15. Click here

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


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

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.

    4. A01IQ6T

      Connect the air conditioning tube and accessory assembly to the cooler condenser assembly with the bolt.

      5.4 N*m 55 kgf*cm 48 in.*lbf
  16. Click here

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


    1. Remove the attached vinyl tape from the pipe and 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. A01IUGE

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

      5.4 N*m 55 kgf*cm 48 in.*lbf
  17. Click here

    INSTALL NO. 3 AIR HOSE

    Note:

    Before installation, remove any oil residue from the inside of the throttle body and tube.


    1. A01IO15E03

      Align the paint mark of the No. 3 air hose with the embossed mark of the throttle body.

      Table 6. Text in Illustration
      *1 Embossed Mark
      *2 Paint Mark
      *a Rear Side
      *b RH Side

    2. Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.

    3. A01IQ7SE01

      Tighten the clamp of the No. 3 air hose on the diesel throttle body side.

      6.5 N*m 66 kgf*cm 58 in.*lbf
      Tip:

      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

    4. A01IP6QE01

      Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

      6.5 N*m 66 kgf*cm 58 in.*lbf
      Tip:

      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

  18. Click here

    INSTALL INTERCOOLER AIR HOSE (for Manual Transaxle)

    Note:

    • Check that the retainer is closed when the connector is inserted.

    • If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.

    • If replacing the hose, apply fresh oil to the O-ring.

    • Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.

    • Do not use a quick connector that has been dropped.


    1. A01ITOHE01

      Install the intercooler air hose to the intercooler and No. 1 air tube and push in the retainer.

      Table 7. Text in Illustration
      *1 Retainer

    2. Tighten the hose clamp.

      6.5 N*m 66 kgf*cm 58 in.*lbf
  19. Click here

    INSTALL INTERCOOLER AIR HOSE (for Automatic Transaxle)

    Note:

    Before installation, remove any oil residue from the inside of the tube.


    1. A01IU8OE04

      Install the intercooler air hose to the No. 1 air tube and intercooler and tighten the 2 hose clamps.

      6.5 N*m 66 kgf*cm 58 in.*lbf
      Table 8. Text in Illustration
      *a Top
      *b View A
      *c RH Side

    2. Install the wire harness clamp with the bolt.

      8.4 N*m 85 kgf*cm 74 in.*lbf

    3. Attach the clamp.

  20. Click here

    CONNECT NO. 2 RADIATOR HOSE


    1. A01ITICE02

      Connect the No. 2 radiator hose and slide the clamp to secure it.

      Tip:

      Position the clamp as illustrated.

      Table 9. Text in Illustration
      *1 Matchmark
      *a Top
      *b RH Side
  21. Click here

    INSTALL NO. 1 RADIATOR HOSE


    1. A01IT0NE02

      Connect the No. 1 radiator hose and slide the 2 clamps to secure it.

      Tip:

      Position clamps A and B as Illustrated.

      Table 10. Text in Illustration
      *1 Matchmark
      *a View A
      *b View B
      *c Top
      *d RH Side
  22. Click here

    INSTALL INJECTOR DRIVER


    1. Install the injector driver bracket with the 4 screws.

      2.0 N*m 20 kgf*cm 18 in.*lbf

    2. Install the injector driver with the 3 bolts.

      6.0 N*m 61 kgf*cm 53 in.*lbf

    3. Attach the clamp and connect the 4 connectors.

  23. Click here

    CONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. Connect the No. 1 water hose clamp bracket to the radiator support with the 2 bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf

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

    3. Connect the No. 1 radiator hose to the No. 1 water hose clamp bracket and slide the clamp to secure it.

  24. Click here

    INSTALL NO. 3 WATER BY-PASS HOSE


    1. Connect the 3 connectors and attach the clamp.

    2. Install the No. 3 water by-pass hose and attach the clamp.

    3. Connect the No. 3 water by-pass hose to the radiator assembly, and slide the clamp to secure it.

  25. Click here

    INSTALL NO. 2 RADIATOR SIDE AIR SEAL


    1. Install the No. 2 radiator side air seal.

  26. Click here

    INSTALL NO. 1 RADIATOR SIDE AIR SEAL


    1. Install the No. 1 radiator side air seal.

  27. Click here

    INSTALL LOW PITCHED HORN ASSEMBLY


    1. Connect the horn connector to install the low pitched horn assembly.

    2. Install the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf
  28. Click here

    CONNECT AMBIENT TEMPERATURE SENSOR


    1. Attach the clamp to install the sensor.

    2. Connect the connector.

  29. Click here

    INSTALL BATTERY CARRIER


    1. A01ISD1

      Install the battery carrier with the 4 bolts.

      19 N*m 189 kgf*cm 14 ft.*lbf

    2. Attach the 2 clamps to connect the wire harness.

  30. Click here

    INSTALL BATTERY TRAY

  31. Click here

    INSTALL BATTERY

  32. Click here

    INSTALL BATTERY INSULATOR

  33. Click here

    INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A01IP71

      Attach the hook of the battery clamp sub-assembly to the battery carrier.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Adjust the battery clamp sub-assembly position.

    4. Tighten the nut and bolt.

      for bolt
      17 N*m 168 kgf*cm 12 ft.*lbf
      for nut
      3.5 N*m 36 kgf*cm 31 in.*lbf
  34. Click here

    INSTALL OIL COOLER ASSEMBLY (for Automatic Transaxle)


    1. Install the oil cooler assembly with the 3 bolts and nut.

      5.5 N*m 56 kgf*cm 49 in.*lbf

    2. Connect the 2 oil cooler hoses and slide the 2 clips.

  35. Click here

    CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  36. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

  37. Click here

    ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

    (Click here)

  38. Click here

    ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

      Standard Capacity
      Item Specified Condition
      w/o Power Heater 7.4 liters (7.8 US qts, 6.5 Imp. qts)
      w/ Power Heater 7.8 liters (8.2 US qts, 6.9 Imp. qts)
      Tip:

      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. A01IQ5WE05

      Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.

      Table 11. Text in Illustration
      *1 Air Release Plug
      A01ISM9 B Line

    4. 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.

    5. Install the cap and air release plug, and warm up the engine sufficiently.

      2.0 N*m 20 kgf*cm 18 in.*lbf

    6. 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.

        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.

        Tip:

        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.

      2. After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern 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 hoses:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    7. A01IQM4

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

      If the coolant level is low, add coolant until the coolant level reaches the reservoir tank FULL line.

  39. Click here

    CHARGE REFRIGERANT (w/ Air Conditioning System)

    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. A01IS7RE26

      Charge refrigerant HFC-134a (R134a).

      Standard
      440 +/-30 g (15.5 +/-1.1 oz)
      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 100 g (3.53 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.

  40. Click here

    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 by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  41. Click here

    INSPECT FOR REFRIGERANT 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.

        Tip:

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

    3. A01IPCYE30

      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.

      Table 12. Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector
  42. Click here

    INSPECT FOR COOLANT LEAK


    1. Remove the radiator reservoir cap.

      CAUTION:

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

    2. A01IU3X

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

    3. Warm up the engine.

    4. Pump the radiator cap tester 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 of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the radiator reservoir cap.

  43. Click here

    INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.

  44. Click here

    INSTALL FRONT LOWER BUMPER ABSORBER


    1. A01IPJ8

      Insert the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.

    2. Install the 4 bolts.

    3. Install the 2 clips.

  45. Click here

    INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  46. Click here

    INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    (Click here)