Diesel Data: Automotive Repair
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Removal and Installation

Part 1 Of 3:




Part 2 Of 3:




Part 3 Of 3:






REMOVAL
1. REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL
2. DRAIN ENGINE COOLANT
3. REMOVE BUMPER COVER
4. 2ZZ-GE: REMOVE AIR PUMP ASSEMBLY
5. REMOVE AIR CLEANER





6. REMOVE ENGINE COOLANT RESERVOIR
a. Disconnect the 3 radiator reservoir hoses.
b. Remove the bolt and engine coolant reservoir.
7. REMOVE RADIATOR ASSEMBLY
a. Disconnect the No. 1 electric cooling fan connector.
b. Disconnect the No. 2 electric cooling fan connector.
c. Disconnect the upper radiator hose.
d. Disconnect the lower radiator hose.
e. Disconnect the 2 A/T oil cooler hoses.





f. Remove the 3 bolts, and disconnect the hood lock.
g. Remove the 2 bolts and center brace.
h. Remove the 2 bolts, 2 nuts and 2 condenser upper supports.
i. w/ Cruise control system:
Remove the bolt, and disconnect the cruise control actuator.
j. Remove the 2 bolts and radiator upper support.
k. Remove the 2 upper radiator support bushings.
l. Remove the radiator assembly.
m. Remove the 2 lower radiator support bushings.
8. REMOVE ELECTRIC COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan assembly.

INSTALLATION
1. INSTALL ELECTRIC COOLING FAN TO RADIATOR
Install the cooling fan with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
2. INSTALL RADIATOR ASSEMBLY
a. Install the 2 lower radiator support bushings.
b. Install the radiator assembly.
c. Install the 2 upper radiator support bushings.





d. Install the radiator upper support with the 2 bolts.
e. w/ Cruise control system: Install the cruise control actuator with the 3 bolts.
f. Install the 2 condenser upper supports with the 2 bolts and nuts.
g. Install the center brace with the 2 bolts.
h. Install the hood lock with the 3 bolts.
i. Connect the 2 A/T oil cooler hoses.
j. Connect the lower radiator hose.
k. Connect the upper radiator hose.
l. Connect the No. 1 electric cooling fan connector.
m. Connect the No. 2 electric cooling fan connector.





3. INSTALL ENGINE COOLANT RESERVOIR
a. Install the engine coolant reservoir with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
b. Connect the 3 radiator reservoir hoses.
4. INSTALL AIR CLEANER
5. 2ZZ-GE: INSTALL AIR PUMP ASSEMBLY
6. INSTALL BUMPER COVER
7. FILL WITH ENGINE COOLANT
8. INSTALL UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL
9. START ENGINE AND CHECK FOR COOLANT LEAKS

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