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Installation [10/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Highlander, 2024 Toyota Highlander, and 2023 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL LOWER RADIATOR SUPPORT 
  2. INSTALL RADIATOR SUPPORT CUSHION 
  3. INSTALL RADIATOR ASSEMBLY 
    1. GTY1106665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engage the 2 guides.
      2. Engage the 2 claws to install the fan with motor assembly to the radiator assembly.
        NOTE:

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

    2. GTY1106667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engage the 2 guides.
      2. Engage the 2 claws to install the radiator assembly (for intercooler) to the radiator assembly.
        NOTE:

        Do not damage the radiator assembly when installing the radiator assembly (for intercooler).

    3. GTY1109413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the radiator assembly (for intercooler) and radiator assembly with the fan with motor assembly to the vehicle body.
        NOTE:

        Do not apply excessive force to the cooler condenser assembly or pipe when installing the radiator assembly (for intercooler) and radiator assembly with the fan with motor assembly.

      2. Engage the 2 guides.
      3. Engage the 2 claws to install the cooler condenser assembly to the radiator assembly (for intercooler).
        NOTE:

        Do not damage the cooler condenser assembly when installing the radiator assembly (for intercooler).

    4. GTY1108924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the cooling fan motor connector and rotate the lever to lock it.
        NOTE:
        • When connecting the cooling fan motor connector, make sure that the connecting parts of the cooling fan motor connector are free of dirt, water or other foreign matter.
        • Be sure to securely connect the cooling fan motor connector.
      2. Engage the 2 clamps to connect the wire harness to the fan with motor assembly.
      3. Connect the cooling fan motor connector.
      4. Engage the clamp to connect the wire harness to the fan with motor assembly.
  4. CONNECT NO. 2 RADIATOR HOSE 
    1. GTY1103732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      *e Right Side of Vehicle *f 2 to 5 mm (0.0787 to 0.197 in.)
      1. Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 radiator hose until it contacts the hose stopper of the radiator assembly.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
      2. Engage the clamp to connect the No. 2 radiator hose to the fan with motor assembly.
  5. CONNECT NO. 3 RADIATOR HOSE 
    1. GTY1107617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      *e Right Side of Vehicle *f 2 to 5 mm (0.0787 to 0.197 in.)
      1. Connect the No. 3 radiator hose to the radiator assembly and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 3 radiator hose until it contacts the hose stopper of the radiator assembly.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  6. CONNECT NO. 5 INTERCOOLER COOLING WATER HOSE 
    1. GTY1105261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      *e Right Side of Vehicle *f 2 to 7 mm (0.0787 to 0.276 in.)
      1. Connect the No. 5 intercooler cooling water hose to the radiator assembly and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 5 intercooler cooling water hose until it contacts the hose stopper of the radiator assembly.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  7. CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE 
    1. GTY1105841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      *e Right Side of Vehicle *f 2 to 7 mm (0.0787 to 0.276 in.)
      1. Connect the No. 1 intercooler cooling water hose to the radiator assembly and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 1 intercooler cooling water hose until it contacts the hose stopper of the radiator assembly.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  8. CONNECT NO. 6 WATER BY-PASS HOSE 
  9. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. GTY1104484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      *e Rear Side of Vehicle *f 2 to 5 mm (0.0787 to 0.197 in.)
      1. Connect the No. 4 water by-pass hose to the radiator assembly and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 4 water by-pass hose until it contacts the hose stopper of the radiator assembly.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  10. INSTALL NO. 2 RADIATOR AIR GUIDE 
  11. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY 

    Upper Radiator Support Sub-assembly 

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

    Inlet Hose 

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

  12. INSTALL NO. 1 RADIATOR AIR GUIDE RH 
  13. INSTALL NO. 1 RADIATOR AIR GUIDE LH 
  14. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 5 [11/2023 - ]

  15. INSTALL HOOD LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 6

  16. INSTALL THERMISTOR ASSEMBLY 

    Refer to INSTALLATION [09/2020 - ]

  17. INSTALL FRONT BUMPER REINFORCEMENT 

    for Sport Package: Refer to PROCEDURE - Step 4

    except Sport Package: Refer to PROCEDURE - Step 4

  18. INSTALL FRONT BUMPER ENERGY ABSORBER 

    for Sport Package: Refer to PROCEDURE - Step 6

    except Sport Package: Refer to PROCEDURE - Step 6

  19. INSTALL HEADLIGHT ASSEMBLY 

    Refer to INSTALLATION [09/2020 - ]

  20. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  21. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  22. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  23. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  24. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 84 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 84 [11/2023 - ]

  25. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 85 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 85 [11/2023 - ]

  26. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 87 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 87 [11/2023 - ]

  27. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 86 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 86 [11/2023 - ]

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