RADIATOR > INSTALLATION

for Preparation Click here

1. Install the fan assembly to the radiator with the 2 guides at the bottom and 3 claws on the top.
   

   Text in Illustration 

   *1

   Guide

2. Install the 2 lower radiator supports to the radiator assembly.
   

3. Install the radiator with fan assembly.
   

   NOTICE:

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

4. Install the condenser assembly with the 4 bolts.
   

   Torque:

   6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

5. Connect the 3 clamps and connector.
   

1. Install the 2 radiator support cushions to the radiator assembly.
   

2. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support.
   

   Torque:

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

3. Connect the 2 connectors.
   

1. Apply MP grease to the sliding areas of the lock.
   

2. Connect the hood lock control cable assembly.
   

3. Install the hood lock assembly with the 2 bolts and hood lock bolt.
   

   Torque:

   7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

   HINT:

   The hood lock nut cap is a non-reusable part. Be sure to install it after performing the Inspect Hood Sub-assembly and Adjust Hood Sub-assembly steps.

4. Connect the connector.
   

1. Connect the outlet No. 1 oil cooler hose.
   

1. Connect the inlet No. 1 oil cooler hose.
   

1. Connect the No. 2 radiator hose and clamp.
   

1. Connect the No. 1 radiator hose.
   

1. Install the radiator reserve tank with the 2 bolts.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

2. Connect the radiator reserve tank hose.
   

1. Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.
   

2. Engage the pin to the radiator support.
   

1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.
   

   Torque:

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

2. Connect the 2 wire harness clamps and vacuum hose clamp.
   

1. Install the battery and battery tray.
   

2. Install the battery clamp with the bolt and nut.
   

   Torque:

   Bolt:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

   Nut:

   3.5 N*m{ 36 kgf*cm , 31 in.*lbf }

3. Connect the positive (+) cable to the positive (+) battery terminal.
   

   Torque:

   6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

NOTICE:

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

1. Tighten the radiator drain cock plug by hand.
   

2. Close the cylinder block drain cock plug (for Bank 1).
   

   Torque:

   13 N*m{ 130 kgf*cm , 9 ft.*lbf }

3. Close the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).
   

   Torque:

   13 N*m{ 130 kgf*cm , 9 ft.*lbf }

4. Loosen the air drain cock plug on the water inlet housing.
   

5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until engine coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.
   

   Torque:

   13 N*m{ 130 kgf*cm , 9 ft.*lbf }

6. Slowly fill the radiator assembly with TOYOTA Super Long Life Coolant (SLLC).
   

   Text in Illustration 

   *a

   Code Mark

   Specified capacity 

   Code Mark "K"	8.8 liters (9.3 US qts, 7.7 Imp. qts)
   Code Mark "J"	8.9 liters (9.4 US qts, 7.8 Imp. qts)

   HINT:

   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).

7. Remove the reserve tank cap.
   

8. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.
   

9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the engine coolant.
   If the engine coolant level is low, add engine coolant.
   

10. Install the radiator cap sub-assembly and reserve tank cap.
    

11. Bleed air from the cooling system.
    

    NOTICE:

    1. Before starting the engine, turn the A/C switch off.
       
    2. Adjust the heater control to the maximum hot setting.
       
    3. Adjust the blower speed to the low setting.
       
    
    

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

       HINT:

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

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

    3. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air.
       

       CAUTION:

       When squeezing the No. 1 and No. 2 radiator hoses:

       1. Wear protective gloves.
          
       2. Be careful as the No. 1 and No. 2 radiator hoses are hot.
          
       3. Keep your hands away from the fans.
          

       NOTICE:

       1. Make sure that the radiator reserve tank assembly still has some engine coolant in it.
          
       2. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
          
       3. If there is not enough engine coolant, the engine may overheat or be seriously damaged.
          
       4. If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.
          

12. Stop the engine, and wait until the engine coolant cools down.
    

13. Add engine coolant to the full line on the radiator reserve tank assembly.
    

CAUTION:

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

NOTICE:

Before performing each inspection, turn the A/C switch OFF.

1. Fill the radiator with coolant and attach a radiator cap tester.
   

2. Warm up the engine.
   

3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 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 heater core, cylinder block and cylinder head.