Page 1249 of 3000
CO–342GR-FE COOLING – RADIATOR
CO
24. REMOVE RADIATOR ASSEMBLY WITH FAN
SHROUD AND FAN MOTOR
(a) Remove the 2 bolts and separate the condenser
assembly from the radiator assembly with fan
shroud and fan motor.
(b) Remove the radiator assembly with fan shroud and
fan motor from the body.
25. REMOVE FAN SHROUD WITH FAN MOTOR
(a) Remove the 2 bolts and fan shroud with fan motor
from the radiator.
26. REMOVE RADIATOR SUPPORT LOWER
(a) Remove the 2 radiator support lowers from the
radiator assembly.
27. REMOVE NO. 2 RADIATOR SUPPORT
(a) Remove the 2 bolts and No. 2 radiator support from
the radiator.
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2GR-FE COOLING – RADIATORCO–35
CO
28. DISCONNECT INLET SUB-ASSEMBLY
(a) Disconnect the inlet hose from the radiator.
(b) Remove the bolt and inlet sub-assembly from the
radiator.
DISASSEMBLY
1. REMOVE RADIATOR WATER INLET
(a) Remove the 2 bolts and radiator water inlet.
2. REMOVE DRAIN PLUG
(a) Remove the drain plug and air drain plug.
(b) Remove the 2 O-rings.
3. REMOVE LOWER RADIATOR TANK
(a) Install the claw to the overhaul handle, inserting it in
the hole in Part A as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
(b) While squeezing the handle, adjust the stopper bolt
so that dimension B is as specified below.
Dimension B:
0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTICE:
If the stopper bolt is not adjusted, the claw may
be damaged.
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CO–362GR-FE COOLING – RADIATOR
CO
(c) Using SST, uncrimp the lock plate by squeezing the
handle until stopped by the stopper bolt.
SST 09230-01010
(d) Lightly tap the bracket of the radiator (or radiator
hose inlet or outlet) with a soft-faced hammer and
remove the tank.
(e) Remove the O-ring.
4. REMOVE UPPER RADIATOR TANK
HINT:
The removal procedure for the upper radiator tank is the
same as that for the lower radiator tank.
INSPECTION
1. INSPECT LOCK PLATE FOR DAMAGE
(a) Inspect the lock plate for damage.
HINT:
• Reassembly of a deformed tank will be
impossible. Therefore, first correct the shape of
the lock plate groove with pliers or a similar tool,
if necessary.
• Water leakage will result if the bottom of the lock
plate groove is damaged or dented. Repair or
replace the locking plate if necessary.
NOTICE:
The radiator can only be crimped 3 times. After
recrimping 2 times, the radiator core must be
replaced.
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Page 1252 of 3000
CO–62GR-FE COOLING – COOLANT
CO
COOLANT
REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER (See page
EM-26)
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
3. DRAIN ENGINE COOLANT
(a) Loosen the radiator drain cock plug.
HINT:
Collect the coolant in a container and dispose of it
according to the regulations in your area.
(b) Remove the radiator cap sub-assembly from the
radiator assembly.
NOTICE:
Do not remove the radiator cap sub-assembly
while the engine and radiator are still hot.
Pressurized, hot engine coolant and steam may
be released and cause serious burns.
(c) Loosen the 2 cylinder block drain cock plugs.
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2GR-FE COOLING – COOLANTCO–7
CO
4. ADD ENGINE COOLANT
(a) Tighten the radiator drain cock plug by hand.
(b) Tighten the 2 cylinder block drain cock plugs.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for
cylinder block drain cock plugs
(c) Remove the air drain cock plug from the water inlet
housing.
(d) Loosen the air drain plug at the top of the radiator 3
or 4 turns.
(e) Add TOYOTA Super Long Life Coolant (SLLC) to
the radiator inlet opening until coolant overflows
from the engine air drain cock hole. Then install the
air drain cock plug to the water inlet housing.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for air
drain cock plug
(f) Continue to add TOYOTA Super Long Life Coolant
(SLLC) to the radiator inlet opening until coolant
overflows from the radiator air drain hole. Then
close the air drain plug at the top of the radiator.
HINT:
If the coolant level at the radiator inlet opening
drops after squeezing the No. 1 and No. 2 radiator
hoses, add coolant.
(g) Slowly fill the radiator with TOYOTA Super Long Life
Coolant (SLLC).
Standard capacity:
11.3 liters (12.0 US qts, 10.0 Imp. qts)
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
consists of a combination of low phosphates and
organic acids).
• Contact your TOYOTA dealer for further details.
NOTICE:
Never use water as a substitute for engine
coolant.
(h) Slowly pour coolant into the radiator reservoir tank
until it reaches the FULL line.
(i) Squeeze the No. 1 and No. 2 radiator hoses several
times by hand, and then check the level of the
coolant.
If the coolant level is low, add coolant.
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CO–82GR-FE COOLING – COOLANT
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(j) 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.
HINT:
The thermostat open timing can be confirmed
by squeezing the inlet radiator hose by hand,
and checking when the engine coolant starts to
flow inside the hose.
(2) Maintain the engine speed at 2500 to 3000
rpm.
(3) Squeeze the inlet and outlet radiator hoses
several times by hand to bleed air.
CAUTION:
When squeezing the radiator hoses:
• Wear protective gloves.
• Be careful as the radiator hoses are hot.
• Keep your hands away from the radiator
fan.
NOTICE:
• Make sure that the radiator reservoir still
has some coolant in it.
• If the coolant temperature gauge
indicates an excessive temperature, turn
off the engine and let it cool.
• If there is not enough coolant, the engine
may overheat or be seriously damaged.
• If the radiator reservoir does not have
enough 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 FULL line.
(k) Stop the engine and wait until the engine coolant
cools down.
(l) Add engine coolant to the FULL line on the radiator
reservoir.
5. INSPECT FOR COOLANT LEAK (See page CO-1)
6. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)
7. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-63)
Page 1255 of 3000
2GR-FE COOLING – RADIATORCO–37
CO
REASSEMBLY
1. INSTALL LOWER RADIATOR TANK
(a) After checking that there are no foreign objects in
the lock plate groove, install a new O-ring without
twisting it.
HINT:
When cleaning the lock plate groove, lightly rub it
with sandpaper without scratching it.
(b) Tap the lock plate with a plastic-faced hammer so
that there is no gap between the lock plate and the
tank.
NOTICE:
Do not tap the areas protruding around the
pipes, brackets or tank ribs.
(c) Install the punch assembly to the overhaul handle,
inserting it in the hole in part A as shown in the
illustration.
SST 09230-01010 (09231-01010, 09231-01020),
09231-14010
(d) While gripping the handle, adjust the stopper bolt so
that dimension B is as specified below.
Dimension B:
8.8 mm (0.347 in.)
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CO–382GR-FE COOLING – RADIATOR
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(e) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this
procedure a few times, fully crimp the lock plate by
squeezing the handle until stopped by the stopper
bolt.
SST 09230-01010 (09231-01010, 09231-01020),
09231-14010
NOTICE:
• Do not crimp the protruding areas around
ports A and brackets B.
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