Technical Repair Instructions

I. OPERATION FLOW CHART

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE

III. PREPARATION

A. PARTS

B. TOOLS

C. COMPONENTS

IV. WORK PROCEDURE

A. RADIATOR REPLACEMENT

1. RECORD THE RADIO STATION PRESETS

2. SET THE SEAT TO MEMORY POS. 1

3. REMOVE THE ENGINE UNDER COVER NO. 1

(a) Remove the 2 clips and 6 bolts

(b) Remove the 2 screws and undercover No. 1.

4. DRAIN THE ENGINE COOLANT

(a) Remove the radiator cap.

CAUTION:
Do not remove the radiator cap while the engine and radiator are hot. Hot engine coolant and steam may blow out from the radiator and cause serious injury.

(b) Drain engine coolant by loosening the lower drain cock plug of the radiator and the cylinder block drain cock plugs.

(c) Tighten the cylinder block drain cock plugs.

Torque:
13 Nm (130 kgf.cm, 9 ft.lbf)

5. REMOVE THE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH AND RH

(a) Remove the 2 screws and 2 clips.

(b) Partially remove the front fender splash shield sub-assembly.

NOTE:
Do not remove the front fender splash assembly completely. Partially remove enough of it to just remove the front bumper cover.

(c) Repeat the same procedure for the opposite side.

6. REMOVE THE FRONT BUMPER COVER

(a) Place masking (protective) tape under the front fender.

^ For vehicles W/ head lamp washer:

(1) Remove the washer hose clip.

(b) Disconnect the fog lamp connectors.

NOTE:
Do not let the connector get wet.

(c) Remove the two screws and 3 clips.

(d) Using a nylon pry tool, disengage the 4 claws and remove the front bumper cover.

7. REMOVE ENGINE ROOM SIDE COVER

(a) Remove the 4 clips and the engine room side cover.

8. REMOVE THE BATTERY

(a) Disconnect the negative battery terminals then the positive battery terminal.

(b) Remove the one bolt and the battery clamp.

(c) Remove the battery.

9. REMOVE THE BATTERY TRAY

10. DISCONNECT RADIATOR HOSE INLET

11. DISCONNECT THE RADIATOR HOSE OUTLET

12. DISCONNECT THE OIL COOLER INLET TUBE NO. 1

13. DISCONNECT THE OIL COOLER OUTLET TUBE NO. 1

14. REMOVE THE COOL AIR INTAKE DUCT SEAL

(a) Using a clip removal tool, remove the 4 clips and cool air intake duct seal.

15. REMOVE THE AIR CLEANER INLET NO. 2

(a) Disconnect the VSV connector.

(b) Remove the 2 wire harness clamps.

(c) Remove the vacuum hoses from the hose clamp.

(d) Remove the 2 bolts and the air cleaner inlet No. 2.

16. REMOVE THE AIR CLEANER INLET NO. 1

(a) Remove the bolt for the resonator assembly.

NOTE:
Do not remove the resonator assembly.

(b) Remove the 1 bolt and the air cleaner inlet No. 1.

17. SEPARATE THE HOOD LOCK ASSEMBLY

(a) Remove the 2 screws, disengage the 2 claws and remove the hood lock control cable cover.

NOTE:
If the cover is damaged, replace the cover.

(b) Using a screw driver, remove the cap.

(c) Remove the 2 bolts and nut, then separate the hood lock assembly.

18. REMOVE THE RADIATOR SUB-ASSEMBLY UPPER

(a) Disconnect the 2 horn connectors.

(b) Remove the 5 bolts and the radiator support sub-assembly upper.

(c) Disconnect the one clip and the air temperature sensor connector.

(d) Remove the 1 lower bolt for the vertical support.

19. REMOVE THE FAN SHROUD

(a) Disconnect the engine coolant reservoir hose.

(b) Disconnect the fan motor connector.

(c) Remove the 4 bolts and the fan shroud.

20. REMOVE THE RADIATOR SUPPORT SUBASSEMBLY UPPER

(a) Remove the 6 bolts and the radiator subassembly upper LH and RH.

21. REMOVE THE NO. 2 RADIATOR ASSEMBLY

(a) Slightly raise the No. 2 radiator assembly.

NOTE:
When removing the radiator support subassembly, raise the cooler condenser. At this point, be careful not to damage the cooler refrigerant discharge pipe and the liquid tube sub-assembly.

(b) Remove the 6 bolts and the radiator support sub-assembly lower RH and LH.

(c) Raise and then, remove the No. 2 radiator subassembly.

(d) Remove the 4 bolt clips from the radiator.

NOTE:
The clips will be reused again.

22. INSTALL THE NO. 2 RADIATOR ASSEMBLY

NOTE:
^ Do not drop or hit any of the circled areas when installing the No. 2 radiator assembly. Applying excessive force to the radiator during installation may seriously shorten the life of the radiator.

(a) Reinstall the 4 bolt clips on to the radiator.

(b) Install the No. 2 radiator assembly.

(c) Slightly lift up on the No. 2 radiator assembly.

NOTE:
When installing the radiator support subassembly, raise the cooler condenser. At this point, be careful not to damage the cooler refrigerant discharge pipe and the liquid tube sub-assembly.

(d) Install the radiator support sub-assembly lower LH and RH with the 6 bolts.

TORQUE:
Bolt A: 5.0 Nm (51 kgf.cm, 44 in.lbf)
Bolt B: 3.9 Nm (40 kgf.cm, 35 in.lbf)

^ Install the radiator support sub-assembly upper LH and RH with the 6 bolts.

TORQUE:
Bolt A: 5.0 Nm (51 kgf.cm, 44 in.lbf)
Bolt B: 3.9 Nm (40 kgf.cm, 35 in.lbf)

23. REINSTALL THE FAN SHROUD

(a) Reinstall the fan shroud with the four bolts.

TORQUE:
8.0 Nm (82 kgf.cm, 71 in.lbf)

(b) Reconnect the fan motor connector.

(c) Reconnect the engine coolant reservoir hose.

24. REINSTALL THE RADIATOR SUPPORT SUBASSEMBLY UPPER

(a) Reinstall the 1 lower bolt for the vertical support.

(b) Reinstall the one clip and reconnect the air temperature sensor.

(c) Reinstall the 5 bolts and the radiator support sub-assembly upper.

NOTE:
Secure the upper member with the retaining claws of the radiator upper support.

TORQUE:
7.8 Nm (71 kgf.cm, 62 in.lbf)

(d) Reconnect the 2 horn connectors.

25. REINSTALL THE HOOD LOCK ASSEMBLY

(a) Reinstall the hood lock assembly with the 2 bolts and the nut.

(b) Adjust the position of the hood lock by moving the hood lock so that the striker enters smoothly.

(c) Tighten the hood lock bolts.

TORQUE:
8.0 Nm (82 kgf.cm, 71 in.lbf)

(d) Reinstall the cap.

(e) Tighten the 2 screws and reinstall the hood lock control cable cover.

26. REINSTALL AIR CLEANER IN LET NO. 1

(a) Reinstall the air cleaner inlet No. 1 with the bolt.

TORQUE:
7.0 Nm (71 kgf.cm, 62 in.lbf)

(b) Reinstall the bolt for the resonator assembly.

27. REINSTALL THE AIR CLEANER INLET NO. 2

(a) Reinstall the 2 bolts and the air cleaner inlet No. 2.

(b) Reinstall the vacuum hoses into the hose clamps.

(c) Reinstall the 2 wire harness clamps.

(d) Reconnect the VSV connector.

28. REINSTALL THE COOL AIR INTAKE DUCT SEAL

(a) Reinstall the 4 clips and cool air intake duct seal.

29. RECONNECT THE OIL COOLER OUTLET TUBE NO. 1

30. RECONNECT THE OIL COOLER INLET TUBE NO. 1

31. RECONNECT THE RADIATOR HOSE OUTLET

32. RECONNECT THE RADIATOR HOSE INLET

33. REINSTALL ENGINE ROOM SIDE COVER

(a) Install the engine room side cover with the 4 clips.

34. REINSTALL THE BATTERY TRAY

35. REINSTALL THE BATTERY

(a) Reinstall the battery.

(b) Reinstall the battery clamp sub-assembly and the one bolt.

TORQUE:
5.5 Nm (56 kgf.cm, 49 in.lbf)

(c) Reconnect the positive battery terminal.

TORQUE:
3.5 Nm (36 kgf.cm, 31 in.lbf)

(d) Reconnect the negative battery terminal.

TORQUE:
3.5 Nm (36 kgf.cm, 31 in.lbf)

36. REINSTALL THE FRONT BUMPER COVER

(a) Reinstall the front bumper cover with the 2 screws and 3 clips.

(b) Reconnect the fog lamp connectors. W/ Head lamp washer

(1) Reinstall the front washer nozzle.

(2) Reinstall the washer hose clip.

37. REINSTALL THE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH AND RH

(a) Reinstall the front fender splash shield with the 2 screws and 2 clips.

(b) Repeat the procedure for the other side of the vehicle.

38. REINSTALL ENGINE UNDER COVER NO. 1

(a) Reinstall the under cover No. 1 with the 2 screws.

(b) Reinstall the 2 clips and 6 bolts.

39. ADD ENGINE COOLANT

(a) Close the lower drain cock plug of the radiator.

(b) Loosen the radiator drain cock plug of the radiator.

(c) Place a vinyl tube on the vent plug located on the radiator drain cock plug.

(d) Fill the radiator with engine coolant until the vinyl tube is filled with coolant.

CAPACITY:
9.7 liters (10.3 US qts, 8.5 Imp. Qts.)

CAUTION:
^ Use only Toyota Super Long Life Coolant (SLLC).

NOTE:
^ Using the improper coolant may damage the engine cooling system.

^ Use coolant which includes more than 50% (freezing protection down to -35°C (- 31°F)) or 60% (freezing protection down to -50°C (-58°F)) ethylene-glycol. Do not use coolant which has more than 70% ethylene-glycol.

^ Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

(e) Tighten the radiator drain cock plug.

(f) Reinstall the radiator cap securely.

(g) Fill the radiator reservoir tank with coolant.

(h) Warm up the engine.

NOTE:
With the A/C, heater, and defroster off, warm up the engine until the fan starts running.

(i) Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine.

(j) Stop the engine and wait until the coolant cools down.

(k) Remove the radiator cap and check the coolant level inside the radiator.

(I) If the coolant level is below the full level, perform the steps from (a) through (k) and repeat the operation until the coolant level remains at the full level.

(m) Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add coolant.

40. INSPECT THE COOLING SYSTEM FOR LEAKS

CAUTION:
Do not remove the radiator cap while the engine and radiator are hot. Hot engine coolant and steam may blow out from the radiator and cause serious injury.

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

(b) Warm up the engine.

(c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 [si) and check that the pressure does not drop.

NOTE:
If the pressure drops, check the hoses, radiator and water pump for leaks. If there are no signs or traces of external coolant leaks, check the heater core, cylinder block, and cylinder head.

41. CHECK THE ATF FLUID LEVEL AND ADJUST AS NECESSARY

42. RESET THE RADIO STATION PRESETS

V. LSC COMPLETION LABEL INSTALLATION

After completing the repair and before returning the vehicle to the owner, an LSC completion label, which is enclosed in the owner's notification, must be affixed to the left front door hinge post, near the check strap.

(a) The label is to be filled out as follows:

^ Write in LSC 4LF.

^ Write in date of repair.

^ Write in your dealer code.

(b) Additional LSC completion labels, in sheets of 50 (P/N 00410-01918), may be ordered through your DMS system.