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Installation [05/2023 - ]: Procedure

  1. INSTALL NO. 5 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 5 radiator support to seal to the radiator assembly.
  2. INSTALL NO. 4 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 4 radiator support to seal to the radiator assembly.
  3. INSTALL NO. 3 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 3 radiator support to seal to the radiator assembly.
  4. INSTALL NO. 2 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 2 radiator support to seal to the radiator assembly.
  5. INSTALL NO. 1 RADIATOR SUPPORT TO SEAL 
    1. Install 2 new No. 1 radiator support to seals to the radiator assembly.
  6. INSTALL LOWER RADIATOR SUPPORT 
    1. Install the 2 lower radiator supports to the radiator assembly.
  7. INSTALL RADIATOR SUPPORT CUSHION 
    1. Install the 2 radiator support cushions to the radiator assembly.
  8. INSTALL FAN WITH MOTOR ASSEMBLY 
    1. Attach the 2 guides.
    2. Install the fan with motor assembly to the radiator assembly with the 2 bolts.
      NOTE:

      Do not damage the radiator assembly when installing the fan with motor assembly.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  9. INSTALL NO. 2 RADIATOR HOSE 
    1. Install the No. 2 radiator hose to the radiator assembly, and slide the clip to secure the hose.
      GTY832698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Clip Installation Angle (120°)
      *c Paint Mark (White)
      *d Claw Center Direction
      *e Variation Range
      *f OK
      *g NG
      *h Upper Side
      *i LH Side
    2. Attach the clamp to install the No. 2 radiator hose to the fan with motor assembly
  10. INSTALL NO. 2 INVERTER COOLING HOSE 
    1. Install the No. 2 inverter cooling hose to the radiator assembly with the 2 clips and clamp.
  11. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH 
    1. Attach the 2 claws to install the rear radiator side air guide plate RH to the radiator assembly.
  12. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Attach the clamp to install the discharge hose sub-assembly to the fan with motor assembly.
  13. INSTALL NO. 1 RADIATOR HOSE 
    1. Install the No. 1 radiator hose to the radiator assembly, and slide the clip to secure the hose.
      GTY818943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Clip Installation Angle (120°)
      *c Paint Mark (White)
      *d Claw Center Direction
      *e Variation Range
      *f OK
      *g NG
      *h Upper Side
      *i LH Side
    2. Attach the clamp and connect the No. 1 radiator hose to the fan with motor assembly
  14. INSTALL NO. 3 INVERTER COOLING HOSE 
    1. Install the No. 3 inverter cooling hose to the radiator assembly with the bolt and clip.

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

  15. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH 
    1. Attach the 3 claws to install the rear radiator side air guide plate LH to the radiator assembly.
  16. INSTALL RADIATOR ASSEMBLY 
    1. Install the radiator assembly together with the fan with motor assembly to the vehicle.
      NOTE:
      • Perform the following procedure with 2 or more people to prevent damage to the radiator assembly.
      • Do not damage the radiator assembly, fan with motor assembly, cooler pipe or cooling hoses when installing them.
    2. Install the front crossmember sub-assembly with the 6 bolts.

      for bolt A 

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

      for bolt B 

      Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

      GTY832326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A
      Bolt B

      Standard Length

      Item Length
      Bolt A 22.5 mm (0.886 in.)
      Bolt B 80 mm (3.15 in.)
    3. Attach the 2 guides.
    4. Attach the 2 claws and connect the cooler condenser assembly to the radiator assembly.
      NOTE:

      Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

  17. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Connect the discharge hose sub-assembly to the cooler condenser assembly.

      Refer to PROCEDURE - Step 2

    2. Connect the discharge hose sub-assembly to the cooler compressor assembly.

      Refer to PROCEDURE - Step 4

  18. CONNECT LIQUID TUBE SUB-ASSEMBLY A 

    Refer to PROCEDURE - Step 3

  19. INSTALL HOOD LOCK SUPPORT BRACE 
    1. Install the hood lock support brace to the front crossmember sub-assembly with the bolt.

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  20. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY 
    1. Install the upper radiator support sub-assembly with the 5 bolts.

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  21. CONNECT ENGINE ROOM MAIN WIRE 
    1. Connect the 3 clamps, 4 connectors and engine room main wire.
  22. CONNECT OIL COOLER INLET HOSE 
    1. Connect the oil cooler inlet hose to the motor cooling cooler, and slide the clip to secure the hose.
      GTY957748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d 0 to 3 mm (0 to 0.118 in.)
      *e 2 to 7 mm (0.0787 to 0.2756 in.) *f Front Side
      *g Rear Side *h Hold Area
      *i Net Protector - -
      NOTE:
      • Align the paint marks on the oil cooler inlet hose to the paint mark on the motor cooling cooler.
      • The hose clamp claw position is within the range shown in the illustration.
      • Do not deform the motor cooling cooler.
      • Water or coolant can be used to assist with inserting the hose, however when using liquid other than water, dilute it to 50% concentration or less before use.
      • Do not install the oil cooler inlet hose while holding the net protector. If force is applied to the net protector, it may cause the oil cooler inlet hose to crack and lead to engine coolant leaks.
  23. CONNECT TRANSMISSION OIL COOLER HOSE 
    1. Connect the transmission oil cooler hose to the radiator assembly, and slide the clip to secure the hose.
      GTY958292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold Area
      *b Net Protector
      NOTE:

      Do not install the transmission oil cooler hose while holding the net protector. If force is applied to the net protector, it may cause the transmission oil cooler hose to crack and lead to transmission fluid leaks.

  24. CONNECT NO. 3 ENGINE WIRE 
    1. Connect the No. 3 engine wire with the 2 bolts.

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

    2. Attach the 2 wire harness clamps and claw.
  25. CONNECT NO. 2 OIL COOLER OUTLET HOSE 
    1. Connect the No. 2 oil cooler outlet hose to the radiator assembly, and slide the clip to secure the hose.
      GTY957793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold Area
      *b Net Protector
      NOTE:

      Do not install the No. 2 oil cooler outlet hose while holding the net protector. If force is applied to the net protector, it may cause the No. 2 oil cooler outlet hose to crack and lead to transmission fluid leaks.

  26. CONNECT NO. 3 INVERTER COOLING HOSE 

    Refer to PROCEDURE - Step 4

  27. CONNECT NO. 2 INVERTER COOLING HOSE 

    Refer to PROCEDURE - Step 5

  28. CONNECT NO. 6 INVERTER COOLING HOSE 
    1. Connect the No. 6 inverter cooling hose to the inverter cooling inlet pipe assembly, and slide the clip to secure the hose.
  29. CONNECT NO. 3 RADIATOR HOSE 
    1. Connect the No. 3 radiator hose to the water inlet with thermostat sub-assembly, and slide the clip to secure the hose.
      GTY779178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Clip Installation Angle (120°)
      *c Paint Mark (Yellow)
      *d Claw Center Direction
      *e Rib
      *f OK
      *g NG
      *h Upper Side
      *i Rear Side
  30. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the radiator assembly, and slide the clip to secure the hose.
      GTY829521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Clip Installation Angle (120°)
      *c Paint Mark (Yellow)
      *d Claw Center Direction
      *e Rib
      *f OK
      *g NG
      *h Upper Side
      *i Rear Side
  31. INSTALL INVERTER WATER PUMP WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  32. INSTALL INVERTER RESERVE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  33. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
    1. Install the radiator reserve tank assembly to the fan with motor assembly with the 2 bolts.

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

    2. Attach the clamp to connect the No. 3 inverter cooling hose to the radiator reserve tank assembly.
    3. Connect the reserve tank outlet hose and slide the clip to secure the hose.
    4. Install the radiator reserve tank hose and slide the 2 clips to secure the hoses.
    5. Connect the 3 connectors, attach the 3 wire harness clamps to connect the engine room main wire from the radiator reserve tank assembly.
  34. INSTALL HOOD LOCK CONTROL CABLE COVER RH 

    Refer to PROCEDURE - Step 14

  35. INSTALL HOOD LOCK CONTROL CABLE COVER LH 

    Refer to PROCEDURE - Step 3

  36. INSTALL HOOD LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  37. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR 

    Refer to PROCEDURE - Step 4

  38. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 9

  39. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  40. INSTALL VEHICLE APPROACHING SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  41. INSTALL RADIATOR SUPPORT OPENING COVER 
    1. Install the 4 screws, attach the 3 claws and install the radiator support opening cover to the front crossmember sub-assembly.

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

  42. INSTALL RADIATOR SUPPORT EXTENSION RH 
    1. Install the 3 screws, attach the 2 claws and install the radiator support extension RH to the radiator support opening cover.

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

    2. Connect the front fender liner RH to the radiator support extension RH with the 3 screws.
  43. INSTALL RADIATOR SUPPORT EXTENSION LH 
    1. Install the 3 screws, attach the 2 claws and install the radiator support extension LH to the radiator support opening cover.

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

    2. Connect the front fender liner LH to the radiator support extension LH with the 3 screws.
  44. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 
    1. Install the No. 2 front bumper reinforcement sub-assembly with the 6 nuts.

      Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

  45. INSTALL AIR CLEANER WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  46. INSTALL NO. 1 AIR CLEANER INLET 

    Refer to PROCEDURE - Step 5

  47. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 7

  48. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  49. INSTALL FRONT BUMPER 

    Refer to INSTALLATION [05/2023 - ]

  50. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 3

  51. ADD ENGINE COOLANT 

    See step  5

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  53. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 3

  54. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  55. INSTALL ENGINE UNDER COVER REINFORCEMENT 
    1. Install the engine under cover reinforcement to the strut bar bracket support sub-assembly with the 4 bolts.

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

  56. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 115

  57. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 118

  58. INSPECT FOR COOLING FAN MOTOR 

    Refer to Cooling Fan Circuit [01/2017 - ]

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