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Cooling System (Mechanical): Cooling: Radiator: Installation

  1. INSTALL RADIATOR SUPPORT LOWER 
    1. Install the 2 supports.
  2. INSTALL RADIATOR SUPPORT CUSHION 
    1. Install the 2 cushions
  3. INSTALL FAN SHROUD WITH FAN AND MOTOR 
    1. Set the fan shroud with fan and motor to the radiator, and attach the claw.
    2. Install the fan shroud with the 2 bolts.

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

      Fig 1: Identifying Fan Shroud Bolts
      G05773371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL RADIATOR ASSEMBLY 
    1. Install the A/C condenser with HV radiator to the radiator with the 4 bolts.

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

      Fig 2: Locating Radiator Bolts
      G05773392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the radiator to the front crossmember.

      HINT:

      Install the radiator to the front side holes of the radiator's lower support.

      Fig 3: Identifying Radiator
      G05773396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT LIQUID TUBE SUB-ASSEMBLY A  (See INSTALLATION )
  6. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  7. CONNECT NO. 7 INVERTER COOLING HOSE 
    1. Connect the cooling hose.
      Fig 4: Locating No. 7 Inverter Cooling Hose
      G05773390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT NO. 2 INVERTER COOLING HOSE 
    1. Connect the cooling hose.
      Fig 5: Locating No. 2 Inverter Cooling Hose
      G05773391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY 
    1. Attach the wire harness to the upper support with the 5 clamps.
      Fig 6: Identifying Wire Harness Clamps
      G05773388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper support with the 5 bolts.

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

      Fig 7: Locating Upper Support Bolts
      G05773389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the 2 clamps to the radiator support LH and RH side.
      4. Fig 8: Locating Upper Radiator Support Sub-Assembly Clamps
      G05773387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 3 connectors.
  10. INSTALL HOOD LOCK ASSEMBLY  (See INSTALLATION )
  11. INSTALL HOOD LOCK CONTROL CABLE COVER 
    1. Attach the claw to install the cover.
    2. Install the 3 screws.
      Fig 9: Locating Hood Lock Control Cable Cover Screws
      G05773386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) 
    1. Install the sensor with the 3 bolts.

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

      Fig 10: Locating Millimeter Wave Radar Sensor Bolts
      G05773385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector
  13. CONNECT WIRE HARNESS 
    1. Attach the 5 clamps and connect the 2 connectors.
      Fig 11: Locating Wire Harness Connectors
      G05773383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the 3 clamps and connect the ECU connector
      3. Fig 12: Locating ECU Connector
      G05773384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OUTLET ENGINE ROOM ECU DUCT  (See INSTALLATION )
  15. CONNECT OUTLET OIL COOLER HOSE 
    1. Connect the hose to the radiator

      HINT

      • The direction of the hose clamp is indicated in the illustration.
      • Insert the cooler hose into the stopper. Set the hose clamp so that the clearance between the hose clamp and stopper is within 2 to 7 mm (0.0787 to 0.276 in.).
  16. CONNECT INLET OIL COOLER HOSE 
    1. Connect the hose to the radiator.

      HINT:

      • The direction of the hose clamp is indicated in the illustration.
      • Insert the cooler hose into the stopper. Set the hose clamp so that the clearance between the hose clamp and stopper is within 2 to 7 mm (0 0787 to 0.276 in.).
        Fig 13: Identifying Inlet Oil Cooler Hose Clamp Position
        G05773406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 2 RADIATOR HOSE 
    1. Install the radiator hose.

      HINT.

      The direction of the hose clamp is indicated in the illustration

      Fig 14: Identifying No. 2 Radiator Hose Clamp Position
      G05773407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 1 RADIATOR HOSE 
    1. Install the radiator hose

      HINT:

      • The direction of the hose clamp is indicated in the illustration
      • Insert the radiator hose into the stopper. Set the hose clamp so that the clearance between the hose clamp and stopper is within 1.0 to 5.0 mm (0.0394 to 0.197 in.).
      • For side (A), assemble the clamp with the water hose set.
        • Fig 15: Identifying No. 1 Radiator Hose Clamp Position
        G05773408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL RADIATOR RESERVOIR ASSEMBLY  (See INSTALLATION  )
  20. INSTALL FRONT BUMPER REINFORCEMENT  (See INSTALLATION )
  21. INSTALL FRONT BUMPER ENERGY ABSORBER  (See INSTALLATION )
  22. INSTALL FRONT BUMPER COVER  (See INSTALLATION )
  23. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH  (See INSTALLATION )
  24. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH  (See INSTALLATION )
  25. INSTALL FRONT FENDER WHEEL OPENING MOULDING LH  (See INSTALLATION )
  26. INSTALL FRONT FENDER WHEEL OPENING MOULDING RH  (See INSTALLATION )
  27. CHARGE REFRIGERANT  (See REPLACEMENT )
  28. ADD ENGINE COOLANT  (See REPLACEMENT  )
  29. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION  )
  30. ADD COOLANT (for Inverter)  (See REPLACEMENT )
  31. INSPECT FOR COOLANT LEAK (for Inverter)  (See INSPECTION PROCEDURE )
  32. INSPECT FOR REFRIGERANT LEAK  (See REPLACEMENT )
  33. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the duct seal with the 4 clips.
  34. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)  (See ADJUSTMENT )
  35. INSTALL RADIATOR GRILLE ASSEMBLY  (See INSTALLATION )
  36. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  37. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  38. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  39. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  40. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY  (See INSTALLATION )
  41. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
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