Section 9 (Cooling (2GR-FSE)): Radiator: Installation

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL RADIATOR ASSEMBLY
1. Install the 2 radiator support cushions and the 2 lower radiator supports to the radiator assembly.
  
  Fig 1: Identifying Radiator Support Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cooling fan assembly to the radiator assembly by engaging them at the bottom. Engage the 3 claws to secure the cooling fan assembly to the radiator assembly.
  
  Fig 2: Installing Cooling Fan Assembly To Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the radiator assembly to the vehicle together with the cooling fan assembly.
  NOTE: Make sure that the cooler condenser assembly and radiator assembly do not come into contact with each other.
  
  Fig 3: Identifying Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RESERVE TANK CAP SUB-ASSEMBLY
1. Install the reserve tank cap sub-assembly to the reserve tank.
  
  Fig 4: Identifying Reserve Tank Cap Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE ROOM ECU OUTLET DUCT
1. Install the engine room ECU outlet duct to the engine room ECU box.
  
  Fig 5: Installing Engine Room ECU Outlet Duct To Engine Room ECU Box
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER CONDENSER ASSEMBLY
1. Install the 4 bolts and the cooler condenser assembly to the radiator assembly.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 6: Identifying Bolts And Cooler Condenser Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR OUTLET HOSE
1. Install the radiator outlet hose to the radiator assembly and secure it with the clips.
  HINT:
  - Make sure that the claws on the clips are facing downward.
  - Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 - 5.0 mm.
  - Connect the hose until it makes contact with the stopper. (Dimension "b" should be less than 2.5 mm)
    
    Fig 7: Identifying Radiator Outlet Hose And Radiator Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR INLET HOSE
1. Install the radiator inlet hose to the radiator assembly and secure it with the clips.
  HINT:
  - Make sure that the claws on the clips are positioned as shown in the illustration.
  - Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.
  - Connect the hose until it makes contact with the stopper. (Dimension "b" should be less than 2.5 mm)
    
    Fig 8: Installing Radiator Inlet Hose To Radiator Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER RADIATOR SUPPORT
1. Install the 5 bolts and the upper radiator support.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 9: Identifying Bolts And Upper Radiator Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 6 wire harness clamps and the No.2 engine room wire.
  
  Fig 10: Identifying Wire Harness Clamps & No. 2 Engine Room Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the clamp and the No.2 cooling fan motor connector.
  
  Fig 11: Identifying Clamp And No 2 Cooling Fan Motor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the clamp and the cooling fan motor connector.
  
  Fig 12: Identifying Clamp And Cooling Fan Motor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 4 wire harness clamps and the 3 connectors.
  
  Fig 13: Identifying Wire Harness Clamps And Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HOOD LOCK ASSEMBLY
1. Install the 2 bolts and the hood lock assembly to the upper radiator support.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
2. Install the hood lock nut and the hood lock nut cap.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 14: Installing Bolts And Hood Lock Assembly To Upper Radiator Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the connector.
  
  Fig 15: Identifying Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HOOD LOCK CONTROL CABLE COVER
1. Connect the clamp, and install the 3 screws and the hood lock control cable cover.
INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) (See INSTALLATION )

Fig 16: Identifying Screws And Hood Lock Control Cable Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See INSTALLATION )
CONNECT NO. 2 VENTILATION HOSE (See INSTALLATION )
INSTALL NO. 1 INLET AIR CLEANER (See INSTALLATION )
INSTALL RADIATOR SUPPORT OPENING COVER
1. Connect the 2 clips, and install the radiator support opening cover.
INSTALL FRONT BUMPER ENERGY ABSORBER
INSTALL FRONT BUMPER ASSEMBLY
ADD ENGINE COOLANT (See COOLANT )
CHECK FOR ENGINE COOLANT LEAKAGE (See ON-VEHICLE INSPECTION )

Fig 17: Identifying Radiator Support Opening Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (See REMOVAL )
PUT VEHICLE UNDER THESE CONDITIONS
1. Adjust the tire pressure to the correct value range.
2. Start the engine and charge the battery.
FOG LIGHT AIMING ADJUSTMENT (See ADJUSTMENT )
FOG LIGHT AIMING INSPECTION (See ADJUSTMENT )
INSTALL ENGINE UNDER COVER
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER RH (See INSTALLATION )
INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION )