RADIATOR REMOVAL

PROCEDURE


  1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  2. DRAIN ENGINE COOLANT

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  3. REMOVE RADIATOR SIDE DEFLECTOR


  4. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

  5. REMOVE NO. 1 RADIATOR AIR GUIDE


    1. B0068JT

      Remove the 4 clips and No. 1 radiator air guide.

      Note

      Do not reuse the clip.

  6. REMOVE NO. 4 AIR HOSE


    1. B0068E9

      Detach the 2 clamps to disconnect the oil return hose from the No. 4 air hose.

    2. Loosen the 2 hose clamps and remove the No. 4 air hose.

  7. REMOVE NO. 2 AIR TUBE


    1. B0068WB

      Detach the 4 clamps to disconnect the oil return hose from the No. 2 air tube.

    2. Loosen the hose clamp and remove the 2 bolts and No. 2 air tube.

  8. REMOVE NO. 1 RADIATOR HOSE


    1. B0068IE

      Slide the 2 hose clamps and remove the No. 1 radiator hose.

  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. B0069F9

      Detach the clamp to disconnect the pressure feed tube assembly from the fan shroud.

    2. Detach the claw and disconnect the vane pump oil reservoir assembly from the No. 1 oil reservoir bracket as shown in the illustration.

  10. REMOVE NO. 1 OIL RESERVOIR BRACKET


    1. B0068XU

      Remove the 3 bolts and No. 1 oil reservoir bracket.

  11. REMOVE RADIATOR RESERVOIR


    1. B0068JA

      Detach the clamp to disconnect the No. 2 water by-pass hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 2 water by-pass hose from the radiator assembly.

    3. B0068JE

      Slide the hose clamp and disconnect the water by-pass hose from the radiator assembly.

    4. Remove the 2 bolts and radiator reservoir.

  12. REMOVE VISCOUS HEATER V BELT (w/ Viscous Heater)

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  13. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)


    1. B0068CB

      Slide the hose clamp and disconnect the No. 1 oil cooler outlet hose from the radiator assembly.

  14. DISCONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)


    1. B0069B9

      Detach the clamp to disconnect the No. 1 oil cooler inlet hose from the fan shroud.

    2. Slide the hose clamp and disconnect the No. 1 oil cooler inlet hose from the radiator assembly.

  15. REMOVE FAN SHROUD


    1. B00689T

      Detach the 6 wire harness clamps.

    2. B0068Y7

      Loosen the 4 nuts holding the fan with fluid coupling assembly.

    3. Remove the fan and generator V belt.

      Click here

    4. B00696U

      Detach the 2 claws and 2 guides to disconnect the fan shroud from the radiator assembly.

    5. Remove the 4 nuts of the fan with fluid coupling assembly and remove the fan shroud together with the fluid coupling assembly.

      Note

      Do not allow the radiator assembly to interfere with other parts.

    6. Remove the fan pulley from the engine water pump assembly.

  16. DISCONNECT NO. 2 RADIATOR HOSE


    1. B0068SN

      Slide the hose clamp and disconnect the No. 2 radiator hose from the radiator assembly.

  17. REMOVE RADIATOR ASSEMBLY


    1. B0068YD

      Remove the 4 bolts.

    2. B0068JP

      w/ Air Conditioning System:

      Detach the 2 claws and 2 guides to disconnect the cooler condenser assembly from radiator assembly.

      Note


      • Do not allow the radiator assembly to interfere with other parts.

      • Do not apply any excessive force to the cooler condenser assembly and cooler pipe.

    3. Remove the radiator assembly from the vehicle.

  18. REMOVE RADIATOR PROTECTOR (w/o Air Conditioning System)


    1. B0068TT

      Detach the 2 claws and 2 guides to remove the radiator protector.

  19. REMOVE RADIATOR DRAIN COCK PLUG


    1. Remove the radiator drain cock plug from the radiator assembly.

    2. Remove the O-ring from the radiator drain cock plug.