Radiator Installation

Install the 6 No. 1 radiator support bushes to the radiator assembly.

Install the 2 No. 2 radiator support bushes to the radiator assembly.

Install the 4 radiator collars to the radiator assembly.

Attach the 2 clamps to install the oil return pipe sub-assembly to the radiator assembly.

Install the intercooler to the radiator with the 4 bolts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Connect the vacuum hose to the intercooler.

Install 2 new No. 2 radiator to support seals to the intercooler.

Install the No. 1 radiator air guide with the 2 bolts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install a new No. 3 radiator to support seal to the No. 1 radiator guide.

Insert the tabs of the radiator collar into the radiator service holes.

Install the radiator assembly the 4 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Attach the 3 claws to install the radiator side deflector LH, and install the clip.

Attach the 3 claws to install the radiator side deflector RH, and install the clip.

Install the front bumper upper retainer with the 3 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Install the front bumper lower cover with the clip and 5 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 ft.*lbf}

Install the fan pulley.

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

NOTICE:

Be careful not to damage the radiator core.

Attach the 2 guides and install the fan shroud with the 2 bolts.

Torque:

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

Temporarily install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.

NOTICE:

1. Make sure to match the paint mark colors on the fan with fluid coupling assembly with the stud bolts of the same color on the engine water pump assembly.
   
2. When installing the fan and generator V belt, make sure to securely tighten the nuts of the fan with fluid coupling assembly so that the fan pulley is properly aligned.
   

Install the fan and generator V belt (LandCruiser RM00000122V00OX_01_0002.html).

Tighten the 4 nuts holding the fan with fluid coupling assembly.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install the viscous heater V belt.

Turn the bolt and adjust the tension of the viscous heater V belt.

Tighten the 2 bolts.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

Check the tension of the viscous heater V belt (LandCruiser RM000001KYZ00IX_01_0003.html).

Connect the oil cooler hose to the radiator assembly and slide the 2 hose clamps to secure the hose.

Attach the 2 clamps and connect the oil cooler hose to the fan shroud with the bolt.

Torque:

5.5 N*m{56 kgf*cm, 49 ft.*lbf}

Install the radiator reservoir assembly with the 3 bolts.

Torque:

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

Attach the 2 clamps to connect the No. 1 water by-pass hose to the fan shroud.

Connect the No. 1 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

Connect the No. 2 water by-pass hose to the water inlet and slide the hose clamp to secure the hose.

Attach the 2 clamps to connect the No. 2 water by-pass hose to the fan shroud.

Install the intercooler air hose and tighten the 2 hose bands to secure the hose.

Torque:

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

Install the No. 2 radiator hose and slide the 2 hose clamps to secure the hose.

Install the No. 2 intercooler air hose and tighten the 2 hose clamps.

Torque:

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

Connect the oil return hose and slide the 2 clips to secure the hose.

Install the No. 1 radiator hose and slide the 2 hose clamps to secure the hose.

Attach the 3 wire harness clamps to connect the No. 3 engine wire to the fan shroud.

Connect the 2 cables to the positive battery terminals.

Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.

Standard Capacity:

Item		Specified Condition
for Manual Transmission	except Cold Area Specification Vehicle	10.1 liters (10.7 US qts, 8.9 Imp. qts)
	for Cold Area Specification Vehicle	11.9 liters (12.6 US qts, 10.5 Imp. qts)
for Automatic Transmission	except Cold Area Specification Vehicle	10.0 liters (10.6 US qts, 8.8 Imp. qts)
	for Cold Area Specification Vehicle	11.8 liters (12.5 US qts, 10.4 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 is a combination of low phosphates and organic acids).

Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.

Install the radiator reservoir cap sub-assembly.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

   NOTICE:

   1. Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
      
   2. Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
      
   3. Make sure that the needle does not show an abnormally high temperature.
      
   4. If there is not enough coolant, the engine may overheat.
      

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

2. Maintain the engine speed at 2000 to 2500 rpm.
   

3. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
   

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.

Remove the radiator reservoir cap sub-assembly.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.

Install the No. 1 engine under cover with the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the upper radiator support seal with the 13 clips.