Section 167 (Engine Cooling System (2AZ-FE)): Radiator: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FAN SHROUD WITH COOLING FAN
1. Install the fan shroud with cooling fan with the 2 bolts to the radiator.
  Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
  
  Fig 1: Installing Fan Shroud With Cooling Fan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR ASSEMBLY
1. Install the 4 fan shroud cushions to the cooler condensers.
2. Set the cooler condenser to the fan shroud.
3. Install the 2 radiator support lower cushions to the fan shroud.
4. Install the radiator with cooler condenser and fan shroud to the radiator support lower.
  
  Fig 2: Installing Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY
1. Install the upper radiator support with the 4 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 3: Installing Upper Radiator Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 FAN SHROUD
1. Attach the 2 claws to install the No. 2 fan shroud and install the 2 bolts.
  Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
  
  Fig 4: Installing No. 2 Fan Shroud
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER RADIATOR SUPPORT BRACKET
1. Install the bracket with the 2 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 5: Installing Upper Radiator Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT HORN CONNECTOR
1. Connect the 2 horn connectors.
CONNECT NO. 2 WATER BY-PASS HOSE
1. Connect the by-pass hose to the radiator and radiator reservoir.
  HINT:
  
  The direction of the hose clamp is indicated in the illustration.
CONNECT NO. 2 RADIATOR HOSE
HINT:

The direction of the hose clamp is indicated in Fig 6.
CONNECT NO. 1 RADIATOR HOSE
HINT:

The direction of the hose clamp is indicated in the illustration.

Fig 6: Installing Radiator Hoses And Hose Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT COOLING FAN MOTOR HARNESS
1. Attach the harness with the 5 clamps.
2. Connect the 2 fan motor connectors.
  
  Fig 7: Installing Fan Motor Harness & Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 WATER BY-PASS PIPE
1. Install the by-pass pipe with the 2 bolts to the upper radiator support.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. Connect the No. 1 radiator hose to the pipe.
  HINT:
  
  The direction of the hose clamp is indicated in Fig 8.
CONNECT NO. 5 WATER BY-PASS HOSE
1. Connect the by-pass hose to the radiator.
  HINT:
  
  The direction of the hose clamp is indicated in Fig 8.
CONNECT NO. 1 WATER BY-PASS HOSE
1. Connect the by-pass hose to the radiator and radiator reservoir.
  HINT:
  
  The direction of the hose clamp is indicated in the illustration.
  
  Fig 8: Connecting Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT HOOD LOCK SWITCH CONNECTOR

Fig 9: Connecting Hood Lock Switch Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See appropriate Step(s) under REASSEMBLY )
INSTALL BATTERY
INSTALL BATTERY CLAMP
1. Attach the hook of the battery clamp to the battery bracket.
2. Temporarily tighten the nut and install the bolt.
3. Adjust the battery clamp's position.
4. Fully tighten the bolt and nut.
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt 5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
ADD ENGINE COOLANT (See COOLANT )
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
INSTALL RADIATOR SUPPORT OPENING COVER