RADIATOR > INSTALLATION

for Preparation Click here

1. Install the radiator assembly with the 2 bolts.
   

   Torque:

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

2. Install the 2 lower radiator supports.
   

3. Install the radiator assembly with the fan shroud.
   

   NOTICE:

   Do not apply any excessive force to the cooler condenser assembly, radiator assembly (for inverter) or pipe when installing the radiator assembly.

4. Connect the 2 connectors and 2 clamps.
   

1. Install the No. 2 fan shroud with the 2 bolts and 2 claws.
   

   Torque:

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

1. Connect the No. 3 water by-pass hose and 4 clamps.
   

1. Connect the No. 1 water by-pass hose.
   

1. Connect the 3 clamps and No. 5 inverter cooling hose to the fan shroud.
   

1. Connect the No. 1 radiator hose.
   

1. Connect the No. 2 radiator hose.
   

1. Install the 2 radiator support cushions.
   

1. Install the hood lock support sub-assembly with the 4 bolts.
   

   Torque:

   13 N*m{ 133 kgf*cm , 10 ft.*lbf }

2. Install the No. 2 water by-pass hose to the hood lock support sub-assembly with the bolt.
   

   Torque:

   19 N*m{ 194 kgf*cm , 14 ft.*lbf }

1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
   

2. Tighten the 3 bolts in the order shown in the illustration.
   

   Torque:

   14 N*m{ 138 kgf*cm , 10 ft.*lbf }

1. Install the cool air intake duct retainer sub-assembly with the 3 bolts.
   

   Torque:

   6.2 N*m{ 63 kgf*cm , 55 in.*lbf }

   NOTICE:

   Tighten the bolts in the order shown in the illustration to install the cool air intake duct retainer sub-assembly.

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

2. Connect the hood lock control cable.
   

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

   Torque:

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

4. Install a new hood lock nut cap.
   

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

2. Connect the hood lock control cable.
   

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

   Torque:

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

4. Install a new hood lock nut cap.
   

5. Engage the clamp.
   

6. Connect the connector.
   

1. Tighten the 3 bolts on the millimeter wave radar sensor assembly.
   

   Torque:

   5.5 N*m{ 56 kgf*cm , 49 in.*lbf }

   HINT:

   Tighten the bolts in the order indicated in the illustration.

2. Connect the connector.
   

1. Install the high pitched horn assembly with the bolt.
   

   Torque:

   19 N*m{ 195 kgf*cm , 14 ft.*lbf }

2. Connect the connector.
   

1. Install the low pitched horn assembly with the bolt.
   

   Torque:

   19 N*m{ 195 kgf*cm , 14 ft.*lbf }

2. Connect the connector.
   

1. Install the air cleaner case with the 2 bolts.
   

   Torque:

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

2. Install the water hose to the hose clamp.
   

3. Install the air cleaner filter element sub-assembly.
   

1. Install the inlet air cleaner assembly to the air cleaner case.
   

2. Install the inlet air cleaner assembly with the 2 bolts and 2 clips.
   

   Torque:

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

3. Connect the wire harness clamp to the inlet air cleaner assembly.
   

4. Install the water hose to the hose clamp.
   

1. Install the air cleaner cap sub-assembly with the 2 clamps.
   

2. Tighten the hose clamp.
   

3. Connect the mass air flow meter connector.
   

4. Connect the wire harness clamp.
   

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.
   

2. Add coolant to B line of the reserve tank.
   

   Text in Illustration 

   *1

   B Line

   Standard Capacity:

   Item	Capacity
   Engine coolant	w/ Exhaust Heat Recirculation System: 6.9 liters (7.3 US qts, 6.1 lmp. qts)
   	w/o Exhaust Heat Recirculation System: 6.5 liters (6.9 US qts, 5.7 lmp. 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).

   NOTICE:

   Never use water as a substitute for engine coolant.

3. Squeeze the radiator hoses several times by hand, and then check the level of the coolant.
   If the coolant level is low, add coolant.
   

4. Put the engine in inspection mode (Click here).
   

5. Install the reserve tank cap.
   

6. 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, allow the coolant to circulate for several minutes. (●1)
      

      HINT:

      The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:

      When squeezing the radiator hose:

      1. Wear protective gloves.
         
      2. Be careful as the radiator hoses are hot.
         
      3. Keep your hands away from the radiator fans.
         

   2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)
      

   3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.
      

7. After the engine has cooled down, check that the coolant level is between the full and low lines.
   

   Text in Illustration 

   *1	Full Line
   *2	Low Line

   If the coolant level is low, add coolant to the full line on the reserve tank.
   

CAUTION:

Do not remove the reserve tank cap 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. Remove the reserve tank cap.
   

2. Fill the reserve tank with coolant, and then attach a radiator cap tester.
   

3. Put the engine in inspection mode (Click here).
   

4. Warm up the engine.
   

5. Using a radiator cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm², 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly, the heater hose around the engine coolant temperature sensor and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
   

6. Remove the radiator cap tester.
   

7. Install the reserve tank cap.
   

1. Install the radiator support opening cover with the 9 clips.
   

1. Engage the claw and install the inverter cover assembly LH.
   

2. Install the 2 clips.
   

1. Engage the 3 clips to install the cover.
   

   NOTICE:

   1. Be sure to engage the clips securely.
      
   2. Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
      

1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.
   

1. Engage the 6 guides.
   

2. Install the deck floor box RH with the clip.
   

1. Install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Install the rear No. 2 floor board.