Section 175 (Engine Cooling System (2GR-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 to the radiator with the 2 bolts.
  Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
  
  Fig 1: Installing Fan Shroud With Cooling Fan To Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR ASSEMBLY
1. Install the 4 fan shroud cushions to the cooler condenser.
2. Set the cooler condenser into 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 lowers.
  
  Fig 2: Installing Fan Shroud Cushions To Cooler Condenser
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER RADIATOR SUPPORT SUBASSEMBLY
1. Install the upper radiator support with the 4 bolts.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 3: Installing Upper Radiator Support With Bolts
  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: Attaching Claws & Installing No. 2 Fan Shroud
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER RADIATOR SUPPORT BRACKET
1. Install the brackets with the 2 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 5: Connecting By-Pass Hose To Radiator & Radiator Reservoir
  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.
  
  Fig 6: Connecting Water By-Pass Hose & Radiator Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 RADIATOR HOSE
HINT:

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

The direction of the hose clamp is indicated in the illustration. (See Fig 6).
CONNECT OIL COOLER OUTLET HOSE
CONNECT OIL COOLER INLET HOSE
CONNECT COOLING FAN ECU HARNESS (w/Trailer Towing System)
1. Attach the harness with the 3 clamps.
2. Connect the 2 fan ECU connectors.
  
  Fig 7: Connecting The 2 Fan ECU Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT COOLING FAN ECU HARNESS (w/o Trailer Towing System)
1. Attach the harness with the 3 clamps.
2. Connect the fan ECU connector.
  
  Fig 8: Attaching Harness With Clamps & Fan ECU Connector
  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: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Connect the No. 1 radiator hose to the pipe.
CONNECT NO. 5 WATER BY-PASS HOSE
1. Connect the by-pass hose to the radiator. (See Fig 9).
CONNECT NO. 1 WATER BY-PASS HOSE
1. Connect the by-pass hose to the radiator reservoir.
  
  Fig 9: Connecting Water By-Pass Hose & Water By-Pass Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT HOOD LOCK SWITCH CONNECTOR

Fig 10: 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 INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY (See appropriate step(s) under INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL RADIATOR SUPPORT OPENING COVER (See appropriate step(s) under INSTALLATION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See appropriate step(s) under INSTALLATION )
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
INSTALL NO. 1 ENGINE UNDER COVER (See appropriate step(s) under INSTALLATION )