RADIATOR (w/ EGR Cooler) INSTALLATION


  1. INSTALL RADIATOR ASSEMBLY


    1. A01DXNFE01

      Install the radiator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  2. CONNECT NO. 1 OIL COOLER TUBE INLET (for Automatic Transmission)

  3. CONNECT NO. 1 OIL COOLER TUBE OUTLET (for Automatic Transmission)

  4. INSTALL FAN SHROUD


    1. Install the fan pulley to the engine water pump.

    2. Install the fan shroud together with the fluid coupling with fan between the radiator and engine component.

      Note

      Be careful not to damage the radiator core.

    3. Install the fluid coupling with fan to the fan pulley with the 4 nuts.

      Tighten the nuts as much as possible by hand.

    4. A01DZVX

      Attach the fan shroud's claws to the radiator.

    5. Install the shroud with the 2 bolts.

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

    6. Install the fan and generator V belt Click here.

    7. Tighten the 4 nuts of the fluid coupling with fan.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    8. A01DVHL

      Install the radiator reservoir with the 2 bolts.

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

    9. Connect the No. 1 and No. 2 water by-pass hoses to the radiator tank upper and lower.

    10. A01DZXC

      Install the oil reservoir with the 3 bolts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

  5. CONNECT RADIATOR HOSE INLET

  6. CONNECT RADIATOR HOSE OUTLET

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  8. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Tighten the radiator drain cock plug by hand.

    3. A01DYVNE01

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 9.8 liters (10.4 US qts, 8.6 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 consists of a combination of low phosphates and organic acids).

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

      If the coolant level is below the F line, add TOYOTA SLLC to the F line.

  9. INSPECT FOR COOLANT LEAK

    Note

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01E06UE01

      Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks.

      If no external leaks are found, check the cylinder block and head.

  10. INSTALL RADIATOR SIDE DEFLECTOR LH


    1. A01E21K

      Install the deflector with the 2 clips and attach the claw.

  11. INSTALL RADIATOR SIDE DEFLECTOR RH


    1. Install the deflector with the 2 clips and attach the claw.

  12. INSTALL RADIATOR GRILLE


    1. Attach the 6 claws to install the radiator grille.

    2. Install the 2 screws and 2 clips.

  13. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  14. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain system need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.