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1GD-FTV COOLING RADIATOR INSTALLATION

PROCEDURE

1.INSTALL RADIATOR DRAIN COCK PLUG 16400B

a. Install a new O-ring to the radiator drain cock plug.

b. Install the radiator drain cock plug to the radiator assembly.

2.INSTALL RADIATOR PROTECTOR (w/o Air Conditioning System) 16546

a. Attach the 2 guides and 2 claws to install the radiator protector to the radiator assembly.

3.INSTALL RADIATOR ASSEMBLY 16400

a. Temporarily install the radiator assembly to the vehicle.

b. w/ Air Conditioning System:

Attach the 2 guides and 2 claws to connect the cooler condenser assembly to the radiator assembly.
NOTICE:
· Do not apply any excessive force to the cooler condenser assembly and cooler pipe.
· Do not allow the radiator assembly to interfere with other parts.

c.

*a Claw

Hook the claw of the radiator assembly as shown in the illustration.

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d.

Install the radiator assembly with the 4 bolts in the order shown in the illustration.
Torque:
22 N*m (224 kgf*cm, 16 ft.*lbf)

4.CONNECT NO. 2 RADIATOR HOSE 16572D

a. Connect the No. 2 radiator hose to the radiator assembly and slide the hose clamp to secure the hose.

5.INSTALL FAN SHROUD 16711

a. Install the fan pulley to the engine water pump assembly.

b. Place the fan shroud together with the fan with fluid coupling assembly between the engine and radiator
assembly.
NOTICE:
Do not allow the radiator assembly to interfere with other parts.

c. Temporarily install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.
NOTICE:
· 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.
· 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.

d. Attach the 2 guides and 2 claws to install the fan shroud to the radiator assembly.

e. Install the fan and generator V belt.

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>INSTALLATION

f. Tighten the 4 nuts holding the fan with fluid coupling assembly.
Torque:
23 N*m (235 kgf*cm, 17 ft.*lbf)

g. Attach the 2 wire harness clamps.

6.CONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission) 32941

a. Connect the No. 1 oil cooler inlet hose to the radiator assembly and slide the hose clamp to secure the
hose.

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b. Attach the clamp to connect the No. 1 oil cooler inlet hose to the fan shroud.

7.CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission) 32942

a. Connect the No. 1 oil cooler outlet tube to the radiator assembly and slide the hose clamp to secure the
hose.

8.INSTALL VISCOUS HEATER V BELT (w/ Viscous Heater) 88359

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>INSTALLATION

9.INSTALL RADIATOR RESERVOIR 16470

a. Install the radiator reservoir with the 2 bolts.

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

b. Connect the water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

c. Connect the No. 2 water by-pass hose to the radiator assembly and slide the hose clamp to secure the
hose.

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

10.INSTALL NO. 1 OIL RESERVOIR BRACKET 44369A

a. Temporarily install the No. 1 oil reservoir bracket with the 3 bolts and tighten the 3 bolts.
Torque:
4.5 N*m (46 kgf*cm, 40 in.*lbf)

11.CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY 44360

a. Attach the claw to connect the vane pump oil reservoir assembly to the vane pump oil reservoir bracket.

b. Attach the clamp to connect the pressure feed tube assembly to the fan shroud.

12.INSTALL NO. 1 RADIATOR HOSE 16571C

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

13.INSTALL NO. 2 AIR TUBE 17362B

a. Install the No. 2 air tube with the 2 bolts and tighten the hose clamp to secure the tube.
Torque:
for bolt : 8.0 N*m (82 kgf*cm, 71 in.*lbf)
for hose clamp : 6.5 N*m (66 kgf*cm, 58 in.*lbf)

b. Attach the 4 clamps to connect the oil return hose to the No. 2 air tube.

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14.INSTALL NO. 4 AIR HOSE 17344E

a. Install the No. 4 air hose and tighten the 2 hose clamps to secure the hose.
Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)

b. Attach the 2 clamps to connect the oil return hose to the No. 4 air hose.

15.ADD ENGINE COOLANT

Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT

16.INSPECT FOR COOLANT LEAK

Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

17.INSTALL NO. 1 RADIATOR AIR GUIDE 16593

a. Install the No. 1 radiator air guide with 4 new clips.

18.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner) 51410

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

19.INSTALL RADIATOR SIDE DEFLECTOR 53293C

· for Steel Type Bumper:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Steel Type
Bumper)>INSTALLATION
· for Resin Type Bumper:
Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Resin Type
Bumper)>INSTALLATION

20.INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 12601B

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>INSTALLATION

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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