RADIATOR (for Sedan) > INSTALLATION



1. INSTALL RADIATOR DRAIN COCK


A106605
  1. Install the radiator drain cock onto the radiator assembly.



2. INSTALL RADIATOR RESERVE TANK HOSE GROMMET


A106604
  1. Install the 2 radiator reserve tank hose grommets onto the radiator assembly.



3. INSTALL RADIATOR SUPPORT CUSHION


A104900
  1. Install the 2 radiator support cushions onto the radiator assembly.



4. INSTALL FAN SHROUD


A104899
  1. Engage the 2 claws and install the fan shroud.



5. INSTALL OIL COOLER INLET HOSE (for Automatic Transaxle)


A106603
  1. Install the oil cooler inlet hose with the clip.



6. INSTALL OIL COOLER OUTLET HOSE (for Automatic Transaxle)


A106602
  1. Install the oil cooler outlet hose with the clip.



7. INSTALL RADIATOR HOSE NO. 2


A104898
  1. Install radiator hose No. 2 with the clip.



8. INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning System)


A104897
  1. Engage the 2 claws and install the radiator assembly into the vehicle.

    NOTICE:
    Do not apply excessive force to the cooler condenser assembly or piping when installing the radiator assembly.


    A104896
  1. Connect the cooling fan motor connector and wire harness clamps.



9. INSTALL RADIATOR ASSEMBLY (w/o Air Conditioning System)


A104896
  1. Install the radiator assembly into the vehicle.

  1. Connect the cooling fan motor connector and wire harness clamps.



10. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)


A117307
  1. Connect the oil cooler inlet hose with the clip.



11. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)


A117306
  1. Connect the oil cooler outlet hose with the clip.



12. CONNECT RADIATOR HOSE NO. 2


A104893
  1. Connect radiator hose No. 2 with the clip.



13. INSTALL RADIATOR HOSE NO. 3


A117310E01
  1. Install radiator hose No. 3 with the 2 clips.



14. CONNECT RADIATOR RESERVOIR TANK HOSE


A117356
  1. Connect the radiator reservoir tank hose to the water filler.



15. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER


A255858
  1. Install the radiator support sub-assembly upper with the 4 bolts.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }
  1. Connect the horn assembly connector.



16. INSTALL HOOD LOCK ASSEMBLY (w/ Theft Deterrent System)


A117345
  1. Temporarily install the hood lock assembly with the 3 bolts.

  1. Connect the engine hood courtesy switch connector.



    A108455
  1. Connect the hood lock control cable assembly to the 2 clamps.



17. INSTALL HOOD LOCK ASSEMBLY (w/o Theft Deterrent System)


A108456
  1. Temporarily install the hood lock assembly with the 3 bolts.



    A108455
  1. Connect the hood lock control cable assembly to the 2 clamps.



18. INSTALL NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)


A109229
  1. Insert the 2 pins of No. 1 cooler cover into the radiator support LWR.

  1. Install No. 1 cooler cover with the 2 clips.



19. INSTALL AIR CLEANER ASSEMBLY


A104895
  1. Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts.

    Torque:
    7.8 N*m{ 80 kgf*cm , 69 in.*lbf }
  1. Connect the wire harness to the air cleaner case.

  1. Install the air cleaner element.



    A117355
  1. Install and lock the air cleaner cap and air cleaner hose and then tighten the air cleaner hose clamp.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }
  1. Connect the ventilation hose to the air cleaner hose.

  1. Connect the vacuum switching valve connector and wire harness clamp.

  1. Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly.

  1. Connect the intake air flow meter connector and wire harness clamp.



20. INSTALL FRONT BUMPER COVER (w/ Large Front Spoiler)


    B209130
  1. Install the 2 clips, screw grommet and the 6 spring nuts.



    B209118
  1. Engage the 6 claws and install the front bumper cover.

  1. Connect the connectors.

    HINT:
    If the vehicle is equipped with fog lights, connect the connector.


    B209124
  1. Install the 6 clips.

  1. Install the 2 screw grommets.

  1. Tighten the 9 bolts and the 7 screws.



    B209115E01
  1. Remove the protective tape.



21. INSTALL FRONT BUMPER COVER (w/ Small Front Spoiler)


    B209119
  1. Install the 2 clips, the screw grommet and the 10 spring nuts.



    B209118
  1. Engage the 6 claws and install the front bumper cover.

  1. Connect the connectors.

    HINT:
    If the vehicle is equipped with fog lights, connect the connectors.


    B209116
  1. Install the 6 clips.

  1. Install the 2 screw grommets.

  1. Tighten the 5 screws and the 3 bolts.



    B209115E01
  1. Remove the protective tape.



22. INSTALL FRONT BUMPER COVER (w/o Front Spoiler)


    B209120
  1. Install the 2 clips and the screw grommet.



    B209118
  1. Engage the 6 claws and install the front bumper cover.

  1. Connect the connectors.

    HINT:
    If the vehicle is equipped with fog lights, connect the connectors.


    B209117
  1. Install the 6 clips.

  1. Install the 2 screw grommets.

  1. Tighten the 7 screws and the 3 bolts.



    B209115E01
  1. Remove the protective tape.



23. INSTALL FRONT SPOILER COVER (w/ Small Front Spoiler)


    B134798
  1. Install the front spoiler cover with the 2 screws and the 10 bolts.



24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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


25. ADD ENGINE COOLANT
  1. Tighten all the plugs.

  1. Pour engine coolant into the radiator assembly until it overflows.

    Capacity:
    M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)
    A/T 4.7 liters (5.0 USqts, 4.4 lmp. qts)

    NOTICE:
    Do not substitute water for engine coolant.

    HINT:
    1. Use of improper engine coolant may damage the engine coolant system.
    2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).
  1. Check the engine coolant level inside the radiator assembly by squeezing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

  1. Install the radiator cap sub-assembly securely.

  1. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

  1. 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.

      HINT:
      The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when when the coolant starts to flow inside the hose.
    2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.

    3. Press the No. 2 radiator hose and No. 3 radiator hose several times by hand to bleed air.

      NOTICE:
      When pressing the radiator houses
      1. Wear protective glove.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away form the radiator fan.
  1. Stop the engine and wait until the coolant cools down.

  1. If the engine coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the engine coolant level stays at the full level.

  1. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.



26. ADJUST HOOD LOCK ASSEMBLY


B106964
  1. Loosen the 3 bolts.

  1. Adjust the hood lock position so that the striker can enter it smoothly.

  1. Tighten the 3 bolts after the adjustment.

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


27. CHECK FOR ENGINE COOLANT LEAKAGE

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    A106594
  1. Fill the radiator assembly with engine coolant, and attach a radiator cap tester.

  1. Pump the tester to 118 kPa (1.2 kgf/cm2, 17.1 psi), and then check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.