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Engine Cooling System: Radiator: Installation

  1. CONNECT INLET SUB-ASSEMBLY 
    1. Connect the inlet hose to the radiator.
    2. Install the inlet sub-assembly to the radiator with the bolt.

      Torque: 7.1 N*m (72 kgf*cm, 63 in.*lbf) 

      Fig 1: Locating Inlet Hose To Radiator
      G05138424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 2 RADIATOR SUPPORT 
    1. Install the No. 2 radiator support to the radiator with the 2 bolts.

      Torque: 12.7 N*m (130 kgf*cm, 112 in.*lbf) 

      Fig 2: Identifying Radiator Support
      G05138423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL RADIATOR SUPPORT LOWER 
    1. Install the 2 radiator support lowers to the radiator.
      Fig 3: Locating Radiator Support Lowers And Radiator Assembly
      G05138422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FAN SHROUD WITH FAN MOTOR 
    1. Install the fan shroud with fan motor to the radiator with the 2 bolts.

      Torque: 6 N*m (61 kgf*cm, 4 ft.*lbf) 

      Fig 4: Identifying Fan Shroud With Fan Motor Radiator And Bolts
      G05138421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL RADIATOR ASSEMBLY WITH FAN SHROUD AND FAN MOTOR 
    1. Install the radiator assembly with fan shroud and fan motor.
      Fig 5: Locating Radiator Assembly With Fan Shroud
      G05138444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the condenser assembly to the radiator assembly with fan shroud and fan motor with the 2 bolts.

      Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

      Fig 6: Locating Condenser Assembly With Bolt
      G05138419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 RADIATOR SUPPORT 
    1. Install the No. 1 radiator support to the radiator assembly with the 6 bolts.

      Torque: Bolt A 

      13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Bolt B 

      3.9 N*m (40 kgf*cm, 35 in.*lbf) 

      Bolt C 

      6 N*m (61 kgf*cm, 4 ft.*lbf) 

    2. Attach the clamp.
      Fig 7: Identifying Radiator Support To Radiator Assembly With Bolts
      G05138446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL RADIATOR SUPPORT CUSHION 
    1. Install the 2 radiator support cushions to the No. 1 radiator support.
      Fig 8: Locating Radiator Support Cushions And Bolts
      G05138417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL PRESSURE FEED TUBE ASSEMBLY 
    1. Install the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 9: Locating Pressure Feed Tube Assembly And Bolts
      G05138416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL HEADLIGHT BRACKET RH 
    1. Install the headlight bracket RH with the 3 nuts.
      Fig 10: Locating Headlight Bracket RH And Nuts
      G05138415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL RADIATOR SIDE DEFLECTOR RH 
    1. Engage the 3 claws to install the radiator side deflector RH.
    Fig 11: Identifying Radiator Side Deflector RH And Claws
    G05138450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL HEADLIGHT ASSEMBLY RH 
    1. The installation procedure of the RH side is the same as the LH side.

      HINT: See INSTALLATION

  12. CONNECT NO. 2 OIL COOLER OUTLET TUBE SUB-ASSEMBLY 
    1. Install the No. 2 oil cooler outlet tube sub-assembly with the 2 bolts.

      Torque: 6 N*m (61 kgf*cm, 4 ft.*lbf) 

      Fig 12: Identifying Oil Cooler Outlet Tube Sub-Assembly With Bolts
      G05138413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the No. 1 transmission oil cooler hoses to the radiator.
    3. Connect the No. 1 oil cooler inlet and No. 1 oil cooler outlet hoses to the No. 2 oil cooler outlet tube sub-assembly.
  13. INSTALL RADIATOR UPPER SUPPORT SUB-ASSEMBLY 
    1. Install the radiator upper support sub-assembly with the 4 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 13: Identifying Radiator Upper Support Sub-Assembly
      G05138412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT COOLING FAN ECU CONNECTOR 
    1. Connect the connector.
    2. Attach the clamp.
      Fig 14: Locating Cooling Fan ECU Connector
      G05138411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY 
    1. Install the hood lock support sub-assembly with the 2 bolts.
      Fig 15: Locating Hood Lock Support Sub-Assembly And Bolts
      G05138410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
    3. Connect the low pitched horn and high pitched horn connectors.
      Fig 16: Connecting Low Pitched Horn And High Pitched Horn Connectors
      G05138455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the ambient temperature sensor connector.
      Fig 17: Locating Ambient Temperature Sensor Connector
      G05138408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL HOOD LOCK ASSEMBLY 
    1. Connect the cable to the hood lock assembly.
      Fig 18: Identifying Hood Lock Assembly With Cable
      G05138407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hood lock assembly with the 3 bolts.

      Torque: 8 N*m (82 kgf*cm, 6 ft.*lbf) 

      3. Fig 19: Locating Hood Lock Bolts
      G05138406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. With Hood Courtesy Switch:
      1. Connect the connector.
  17. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR 
    1. Engage the 4 claws to install the hood lock release lever protector.
      Fig 20: Identifying Hood Lock Release Lever Protector And Claws
      G05138405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the radiator.
      Fig 21: Locating Radiator Hose
      G05138404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the radiator.
      Fig 22: Locating Upper And Lower Radiator Hose Clamps
      G05138403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. CONNECT RADIATOR RESERVE TANK HOSE OR PIPE 
    1. Connect the radiator reserve tank hose or pipe to the radiator.
    Fig 23: Locating Radiator Reserve Tank Hose And Pipe
    G05138402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  22. INSTALL FRONT BUMPER ENERGY ABSORBER 
  23. INSTALL FRONT BUMPER ASSEMBLY  (See INSTALLATION )
  24. INSTALL BATTERY  (See INSTALLATION )
  25. INSTALL NO. 2 AIR CLEANER INLET  (See INSTALLATION )
  26. ADD ENGINE COOLANT  (See REPLACEMENT  )
  27. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION  )
  28. ADD AUTOMATIC TRANSAXLE FLUID 
  29. CHECK AUTOMATIC TRANSAXLE FLUID  (See ON-VEHICLE INSPECTION )
  30. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  31. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  32. VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT  (See ADJUSTMENT )
  33. PREPARATION FOR HEADLIGHT AIMING (Using a tester)  (See ADJUSTMENT )
  34. PREPARATION FOR HEADLIGHT AIMING (Using a screen)  (See ADJUSTMENT )
  35. HEADLIGHT AIMING INSPECTION  (See ADJUSTMENT )
  36. HEADLIGHT AIMING ADJUSTMENT  (See ADJUSTMENT )
  37. VEHICLE PREPARATION FOR FOG LIGHT AIM ADJUSTMENT (w/ Fog Light)  (See ADJUSTMENT )
  38. PREPARATION FOR FOG LIGHT AIMING (Using a screen) (w/ Fog Light)  (See ADJUSTMENT )
  39. FOG LIGHT AIMING INSPECTION (w/ Fog Light)  (See ADJUSTMENT )
  40. FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light)  (See ADJUSTMENT )
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