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Cooling (4GR-FSE): Radiator: Installation

  1. INSTALL RADIATOR ASSEMBLY 
    1. Install the 2 radiator support cushions and the 2 lower radiator supports to the radiator assembly.
      Fig 1: Installing Radiator Support Cushions
      G05828890Courtesy 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
      G05828904Courtesy 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: Installing Radiator Assembly
      G05808288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL RESERVE TANK CAP SUB-ASSEMBLY 
    1. Install the reserve tank cap sub-assembly to the reserve tank.
      Fig 4: Installing Reserve Tank Cap Sub-Assembly
      G05828800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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
      G05808267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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: Installing Bolts And Cooler Condenser Assembly
      G05828798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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: Installing Radiator Outlet Hose
        G05828822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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
        G05828823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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: Installing Bolts And Upper Radiator Support
      G05828795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 wire harness clamps and the No.2 engine room wire.
      Fig 10: Installing Wire Harness Clamps And Engine Room Wire
      G05828794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the clamp and the No.2 cooling fan motor connector.
      Fig 11: Connecting Clamp And Cooling Fan Motor Connector
      G05828793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the clamp and the cooling fan motor connector.
      Fig 12: Connecting Clamp And Cooling Fan Motor Connector
      G05828792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 4 wire harness clamps and the 3 connectors.
      Fig 13: Connecting Wire Harness Clamps And Connectors
      G05828915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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
      G05828790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
      Fig 15: Connecting Connector
      G05828789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL HOOD LOCK CONTROL CABLE COVER 
    1. Connect the clamp, and install the 3 screws and the hood lock control cable cover.
    Fig 16: Installing Hood Lock Control Cable Cover With Screws
    G05828788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)  (See INSTALLATION )
  11. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  12. CONNECT NO. 2 VENTILATION HOSE  (See INSTALLATION )
  13. INSTALL NO. 1 INLET AIR CLEANER  (See INSTALLATION )
  14. INSTALL RADIATOR SUPPORT OPENING COVER 
    1. Connect the 2 clips, and install the radiator support opening cover.
      2. Fig 17: Installing Radiator Support Opening Cover
      G05828787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT BUMPER ENERGY ABSORBER 
  16. INSTALL FRONT BUMPER ASSEMBLY 
  17. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION  )
  18. CHECK FOR ENGINE COOLANT LEAKAGE  (See ON-VEHICLE INSPECTION  )
  19. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY  (See ADJUSTMENT )
  20. PUT VEHICLE UNDER THESE CONDITIONS 
    1. Adjust the tire pressure to the correct value range.
    2. Start the engine and charge the battery.
  21. FOG LIGHT AIMING ADJUSTMENT  (See ADJUSTMENT )
  22. FOG LIGHT AIMING INSPECTION  (See ADJUSTMENT )
  23. INSTALL ENGINE UNDER COVER 
  24. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  25. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  26. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  27. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
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