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Installation [12/2021 - ]: Procedure

  1. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL 
  2. INSTALL UPPER RADIATOR AIR GUIDE PLATE 
  3. INSTALL COOLER CONDENSER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  4. INSTALL COOLER BRACKET 

    Refer to PROCEDURE - Step 2

  5. INSTALL NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY 
    Refer to PROCEDURE - Step 3
  6. INSTALL BLOWER ASSEMBLY WITH SHROUD 

    Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  7. INSTALL NO. 2 RADIATOR HOSE 
    1. GTY1131889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 7.0 mm (0.0787 to 0.276 in.) *d 30°
      *e Upper Side *f RH Side
      1. Install the No. 2 radiator hose to the radiator assembly and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 2 radiator hose is securely inserted to the stopper.
  8. INSTALL RADIATOR WITH COOLER CONDENSER ASSEMBLY 
    1. GTY1081159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the radiator with cooler condenser assembly to the vehicle.
        NOTE:
        • Perform the following procedure with 2 or more people to prevent damage to the radiator with cooler condenser assembly.
        • When removing the radiator with cooler condenser assembly from the vehicle, do not apply excessive force to the cooler pipe or cooling hoses.
      2. Set the radiator bracket hooks into the radiator support holes.
      3. Install the radiator with cooler condenser assembly with the 6 bolts.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

      4. Attach the clamp and connect the connector.
  9. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 
    1. GTY1080582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and connecting part of the cooler condenser assembly and then sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose.

        Compressor Oil

        Refrigerant Compressor Oil
        HFC-134a (R134a) ND-OIL 8 or equivalent
        HFO-1234yf (R1234yf) ND-OIL 12 or equivalent
      2. Install the O-ring to the No. 1 cooler refrigerant discharge hose.
        NOTE:

        Keep the O-ring and O-ring fitting surface free of foreign matter.

      3. Connect the No. 1 cooler refrigerant discharge hose to the cooler condenser assembly with the bolt.

        Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

        NOTE:

        Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed.)

  10. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY 
    1. GTY1081113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the vinyl tape from the air conditioning tube and accessory assembly and connecting part of the No. 2 air conditioning tube and accessory assembly and then sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

        Compressor Oil

        Refrigerant Compressor Oil
        HFC-134a (R134a) ND-OIL 8 or equivalent
        HFO-1234yf (R1234yf) ND-OIL 12 or equivalent
      2. Install the O-ring to the air conditioning tube and accessory assembly.
        NOTE:

        Keep the O-ring and O-ring fitting surface free of foreign matter.

      3. Connect the air conditioning tube and accessory assembly to the No. 2 air conditioning tube and accessory assembly with the bolt.

        Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

        NOTE:

        Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed.)

  11. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH 
  12. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH 
  13. INSTALL NO. 2 RADIATOR BRACKET 
    1. GTY1080727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Hook the claw of the No. 2 radiator bracket as shown in the illustration.
      2. Install the No. 2 radiator bracket with the 4 bolts.

        Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

  14. CONNECT FRONT RADIATOR SIDE AIR GUIDE PLATE LH 
  15. CONNECT NO. 8 WATER BY-PASS HOSE 
  16. CONNECT NO. 9 WATER BY-PASS HOSE 
  17. INSTALL NO. 1 RADIATOR BRACKET 
    1. GTY1081056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Hook the claw of the No. 1 radiator bracket as shown in the illustration.
      2. Install the No. 1 radiator bracket with the 4 bolts.

        Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

  18. CONNECT FRONT WATER BY-PASS JOINT SUB-ASSEMBLY 

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

  19. CONNECT WATER HOSE JOINT 

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

  20. CONNECT NO. 1 WATER BY-PASS PIPE 

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

  21. CONNECT ELECTRIC WATER PUMP ASSEMBLY 

    Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  22. INSTALL CONNECTOR COVER 
  23. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL 
  24. INSTALL NO. 2 INTERCOOLER COOLING RADIATOR ASSEMBLY 

    Refer to INSTALLATION [12/2021 - ]

  25. INSTALL FAN SHROUD 
    1. GTY1077664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the fan pulley to the engine water pump assembly.
      2. Place the fan shroud together with the fluid coupling assembly with fan between the radiator and engine.
        NOTE:

        Be careful not to damage the radiator core.

      3. Temporarily install the fluid coupling assembly with fan to the engine water pump assembly with the 4 nuts. Tighten the nuts as much as possible by hand.
        NOTE:

        Align the paint marks on the head of the engine water pump stud bolt with the paint marks of the same color on the outer edge of the fluid coupling flange and set the fluid coupling to the engine water pump assembly.

      4. Attach the claws of the fan shroud to the radiator as shown in the illustration.
      5. Install the fan shroud with the 2 bolts.

        Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

      6. Tighten the 4 nuts of the fluid coupling assembly with fan.

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  26. INSTALL FAN AND GENERATOR V BELT 
    Refer to PROCEDURE - Step 1
  27. INSTALL NO. 1 AIR TUBE SUPPORT 

    Refer to PROCEDURE - Step 2

  28. CONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 3

  29. INSTALL NO. 1 V BELT (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) 
    Refer to PROCEDURE - Step 4
  30. INSTALL COOLING FAN WIRE 
    1. GTY1081157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the cooling fan wire with the 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      2. Connect the connector A.
      3. Connect the connector B and lock it with the lever.
        NOTE:
        • When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other parts.
        • Make sure that the lever are securely locked.
  31. CONNECT OIL COOLER TUBE SUB-ASSEMBLY 
    1. GTY1080716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *d 2.0 to 7.0 mm (0.0787 to 0.276 in.)
      *e 60° - -
      1. Connect the oil cooler tube sub-assembly to the fan shroud with the 3 bolts.

        Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

        NOTE:

        Tightening order: Temporarily install bolt A → Tighten bolt B → Tighten bolt C → Tighten bolt A

      2. Connect the oil cooler tube sub-assembly to the radiator assembly and slide the hose clip to secure it as shown in the illustration.
        NOTE:

        Make sure the oil cooler tube sub-assembly is securely inserted to the stopper.

  32. CONNECT OIL COOLER ASSEMBLY WITH OIL COOLER HOSE 
    1. GTY1081050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 5.0 mm (0.0787 to 0.197 in.) *d -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)
      *e 2.0 to 7.0 mm (0.0787 to 0.276 in.) *f 120°
      *g 60° *h Upper Side
      *i RH Side - -
      1. Connect the oil cooler assembly with oil cooler hose to the fan shroud with the 3 bolts.

        Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

        NOTE:

        Tightening order: Tighten bolt A → Tighten bolt B → Tighten bolt C

      2. Connect the oil cooler assembly with oil cooler hose to the radiator assembly and slide the 2 hose clips to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the oil cooler assembly with oil cooler hose is securely inserted to the stopper.
      3. Attach the clamp.
  33. CONNECT NO. 2 WATER BY-PASS PIPE 

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

  34. CONNECT NO. 2 RADIATOR HOSE 
    1. GTY1132850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 7.0 mm (0.0787 to 0.276 in.) *d 30°
      *e Upper Side *f RH Side
      1. Attach the clamp.
      2. Connect the No. 2 radiator hose to the water inlet pipe and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 2 radiator hose is securely inserted to the stopper.
  35. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    NOTE:

    If the engine coolant temperature sensor has been struck or dropped, replace it.
    1. GTY1081347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side *b LH Side
      *c 45° - -
      1. Apply a light coat of engine coolant to the O-ring of the engine coolant temperature sensor.
      2. Install the engine coolant temperature sensor to the radiator assembly with a new clip.
        NOTE:
        • If reusing the engine coolant temperature sensor, be sure to inspect the O-ring.
        • Make sure that the O-ring is not cracked or moved out of place when installing the engine coolant temperature sensor.
      3. Connect the engine coolant temperature sensor connector.
      4. Attach the clamp.
  36. INSTALL NO. 1 RADIATOR HOSE 
    1. GTY1132851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 7.0 mm (0.0787 to 0.276 in.) *d 30°
      *e Upper Side *f RH Side
      *g Rear Side *h LH Side
      1. Install the No. 1 radiator hose to the water outlet pipe and radiator assembly and slide the 2 hose clips to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 1 radiator hose is securely inserted to the stopper.
  37. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
    1. GTY1133778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 5.0 mm (0.0787 to 0.197 in.) *d 30°
      *e Upper Side *f RH Side
      Bolt A Bolt B
      1. Install the radiator reserve tank assembly to the radiator assembly with the 3 bolts.

        Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

      2. Connect the radiator reserve tank hose to the radiator assembly and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the radiator reserve tank hose is securely inserted to the stopper.
  38. CONNECT NO. 2 WATER BY-PASS HOSE 
    1. GTY1131377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 5.0 mm (0.0787 to 0.197 in.) *d 25°
      *e Rear Side *f RH Side
      1. Connect the No. 2 water by-pass hose to the water inlet pipe and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 2 water by-pass hose is securely inserted to the stopper.
  39. CONNECT WATER BY-PASS HOSE ASSEMBLY 
    1. GTY1081231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the Water By-pass Hose Assembly Insert the Retainer in the Direction of the Arrow Shown in the Illustration.
      1. Connect the water by-pass hose assembly to the intercooler pipe and slide the retainer to secure it as shown in the illustration.
        NOTE:
        • Push in the retainer until a click sound is heard.
        • Pull on the water by-pass hose assembly to confirm that the hose is securely connected.
  40. CONNECT WATER BY-PASS HOSE 
    1. GTY1080812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 5.0 mm (0.0787 to 0.1969 in.) *d 60°
      *e Upper Side *f RH Side
      1. Connect the water by-pass hose to the radiator reserve tank assembly and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the water by-pass hose is securely inserted to the stopper.
  41. INSTALL AIR CLEANER ASSEMBLY LH WITH AIR CLEANER HOSE ASSEMBLY LH 
    Refer to PROCEDURE - Step 2
  42. INSTALL AIR CLEANER ASSEMBLY RH WITH AIR CLEANER HOSE ASSEMBLY RH 
    Refer to PROCEDURE - Step 3
  43. INSTALL FRONT BUMPER ASSEMBLY 
  44. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 
  45. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 3

  46. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 3

  47. WARM UP ENGINE 
  48. INSPECT FOR REFRIGERANT LEAK 
  49. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 3

  50. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  51. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
    Refer to PROCEDURE - Step 91
  52. INSTALL UPPER RADIATOR SUPPORT SEAL 
  53. INSTALL V-BANK COVER SUB-ASSEMBLY 
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