Radiator Installation

Install the radiator with the 4 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

w/ Airbag System:

1. Attach the 4 clamps to the radiator.
   

Connect the oil cooler inlet hose to the radiator.

Connect the oil cooler outlet hose to the radiator.

Install the fan pulley to the engine water pump.

Place the shroud together with the fluid coupling fan between the radiator and engine.

NOTICE:

Be careful not to damage the radiator core.

Install the coupling fan to the engine water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

Attach the claws of the shroud to the radiator as shown in the illustration.

Install the shroud with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the fan and generator V belt (HILUX_TGN26 RM000000YMN01OX_01_0001.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Connect the reservoir hose to the upper radiator tank.

Install the air pump inlet to the upper radiator tank with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Connect the radiator hose outlet to the radiator.

Connect the radiator hose inlet to the radiator.

Tighten the cylinder block water drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Add engine coolant.

Standard capacity:

Item	Specified Condition
for Automatic Transmission	8.1 liters (8.6 US qts, 7.1 Imp. qts)
for Manual Transmission	7.8 liters (8.2 US qts, 6.9 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Press the radiator hose inlet and radiator hose outlet several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the radiator hose inlet will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the radiator hose inlet and radiator hose outlet several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the radiator hose outlet by hand and checking when the engine coolant starts to flow inside the hose.
   

Stop the engine and wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

Remove the radiator cap.

CAUTION:

To avoid being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.
If the pressure drops, check the hose, radiator and water pump for leakage. If no external leakage is found, check the heater core, cylinder block and cylinder head.

Install the radiator cap.

Install the deflector with the 3 clips and attach the claw.

Install the deflector with the 3 clips and attach the claw.

Attach the 6 claws to install the radiator grille.

Install the 2 screws and 2 clips.