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Radiator ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. DRAIN ENGINE COOLANT (See  REPLACEMENT   ) 
  3. REMOVE ENGINE UNDER COVER NO.1 
  4. REMOVE ENGINE UNDER COVER NO.2 
  5. REMOVE RADIATOR LOWER AIR DEFLECTOR (See  STARTER  ) 
  6. REMOVE BATTERY 
  7. REMOVE BATTERY TRAY 
  8. REMOVE AIR CLEANER INLET ASSY (See  STARTER  ) 
  9. REMOVE AIR CLEANER ASSY (See  STARTER  ) 
  10. REMOVE AIR CLEANER BRACKET (See  STARTER  ) 
  11. REMOVE AIR CLEANER INLET NO.1 (See  STARTER  ) 
  12. DISCONNECT RADIATOR HOSE INLET 
  13. DISCONNECT RADIATOR HOSE OUTLET 
  14. DISCONNECT OIL COOLER INLET HOSE 
  15. DISCONNECT OIL COOLER OUTLET HOSE 
  16. REMOVE HOOD LOCK RELEASE LEVER PROTECTOR 
    1. Using a screwdriver with the tip wrapped in tape, remove the protector.
      NOTE: Removing the protector damages the clips inside the protector, therefore it is necessary to use a new protector when installing.
      Fig 1: Identifying Hood Lock
      G00915141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. SEPARATE HOOD LOCK ASSY 
    1. Disconnect the hood switch connector.
    2. Remove the 3 bolts, then separate the hood lock.
      Fig 2: Identifying 3 Bolt
      G00915142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE RADIATOR SUPPORT UPPER 
    1. Disconnect the horn connectors.
    2. Remove the 5 bolts, then remove the radiator support upper.
      Fig 3: Identifying Bolts
      G00915143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE RADIATOR ASSY 
    1. Disconnect the 2 wire harness connectors.
    2. Remove the radiator from the vehicle.
      Fig 4: Identifying Wire Harness Connectors
      G00915144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE RADIATOR SUPPORT CUSHION 
    1. Remove the 2 radiator support cushions from the radiator.
  21. REMOVE RADIATOR SUPPORT LOWER 
    1. Remove the 2 radiator support lowers from the radiator.
  22. REMOVE FAN SHROUD SUB-ASSY 
    1. Disconnect the temperature detect switch connector.
    2. Remove the 3 bolts, then remove the fan shroud with motor.
      Fig 5: Removing Fan Shroud With Motor
      G00915145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TEMPERATURE DETECT SWITCH 
  24. REPLACE RADIATOR ASSY 
  25. INSTALL FAN SHROUD SUB-ASSY 

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

  26. INSTALL RADIATOR SUPPORT UPPER 

    Torque: 14 N.m (142 kgf.cm, 10 ft.lbf) 

  27. INSTALL HOOD LOCK ASSY 

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

  28. INSTALL AIR CLEANER INLET NO.1 (See  STARTER  ) 
  29. INSTALL AIR CLEANER BRACKET (See  STARTER  ) 
  30. INSTALL AIR CLEANER ASSY (See  STARTER  ) 
  31. INSTALL AIR CLEANER INLET ASSY (See  STARTER  ) 
  32. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  33. ADD ENGINE COOLANT (See  REPLACEMENT   ) 
  34. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION   ) 
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