RADIATOR INSTALLATION


  1. INSTALL FAN SHROUD


    1. A01ITJS

      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. A01ITN8E01

      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 RADIATOR ASSEMBLY

    A01ISCM

    1. Install the 2 lower radiator supports.

    2. Install the radiator together with the fan shroud.

    3. A01IT13

      Connect the cooling fan ECU connector and wire harness clamp.

  4. CONNECT NO. 2 RADIATOR HOSE


    1. A01IT9EE01

      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.

  5. CONNECT NO. 3 RADIATOR HOSE


    1. A01IQQGE01

      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.

  6. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A01IORWE01

      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.

  7. CONNECT NO. 1 WATER BY-PASS HOSE


    1. A01IRB5E01

      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.

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

    A01IS8M

    1. Attach the claw to install the cooler bracket.

    2. A01INL8

      Attach the clamp to install the sensor.

    3. Connect the connector.

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

    A01IR4A

    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

  10. CONNECT SUCTION PIPE 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 pipe joint.

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. A01IS4X

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

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

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


    1. Remove the attached vinyl tape from the hose 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. A01IS12

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

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

  12. INSTALL NO. 2 FAN SHROUD


    1. A01IR1J

      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. A01IUPR

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

  13. INSTALL RADIATOR SUPPORT CUSHION


    1. A01IRA5

      Install the 2 cushions.

  14. INSTALL UPPER RADIATOR SUPPORT


    1. A01IOMT

      Install the upper radiator support with the 4 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 horn connector.

    4. Connect the hood lock cable.

  15. INSTALL BATTERY TRAY

  16. INSTALL BATTERY

  17. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A01IQN6E01

      Install the battery clamp with the bolt and nut.

      Torque:
      for bolt
      17 N*m  { 169 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 }

  18. INSTALL NO. 1 WATER HOSE CLAMP BRACKET

    A01IP24

    1. Attach the 2 claws and install the water hose clamp bracket to the upper radiator support with the 2 bolts.

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

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  20. INSTALL FRONT BUMPER COVER


    1. Install the front bumper cover Click here.

  21. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug.

    2. A01IRFF

      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 5-bladed fan 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      7-bladed fan 6.3 liters (6.7 US qts, 5.5 Imp. qts)
      for CVT 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. A01IRFF

      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.

  22. 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)
      A01IS7RE26

      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.

  23. 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.

  24. 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. A01IPCYE30
      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.

  25. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir 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. A01IPAH

      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.

  26. INSTALL NO. 1 ENGINE UNDER COVER


    1. A01ISXU

      Install the under cover with the 11 clips and 6 bolts.

  27. INSPECT HOOD SUB-ASSEMBLY


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

      A01IOPIE01
      Standard
      Area Specified Condition Area Specified Condition
      A 2.35 to 6.35 mm (0.0925 to 0.250 in.) B -1.15 to 2.85 mm (-0.0453 to 0.112 in.)
      C (Reference) 2.75 to 6.75 mm (0.108 to 0.266 in.) D (Reference) -1.75 to 2.25 mm (-0.0689 to 0.0886 in.)
      E 1.7 to 4.7 mm (0.0787 to 0.185 in.) F -0.2 to 2.8 mm (-0.0079 to 0.110 in.)

  28. ADJUST HOOD SUB-ASSEMBLY


    1. A01IOOB

      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. A01IN51

      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. A01IO5A

        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 }

  29. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A01IQMS

      Attach the 4 hooks to install the radiator support opening cover.

    2. Install the 3 clips.

  30. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A01IRS7

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.