Radiator replacement
Use this guide at your own risk and double-check everything - procedure and specifications. The factory service manual can be a great help.
Tools & Supplies – you may not need everything listed:
-
Factory Service Manual -
Components diagram -
Removal instructions
- Radiator
- Flathead screwdriver
- Toyota Red Coolant (Not the premixed stuff, I used slightly over 1 gallon)
- Distilled Water (I used steam distilled water, slightly over 1 gallon)
- Vice grips / Pliers
- Ratchet
- Ratchet extensions
- Torque wrench
- 10, 12, 14mm sockets
- Funnel
- 5/16" inside diameter tubing
1) Put your pets inside. Animals are attracted to ethylene glycol (your coolant) and will want to lick it up. A very small amount of coolant can kill an animal. If your pet does lick up any coolant you need to go to a veterinarian immediately and if you just drained your coolant you hopefully have an extra vehicle on hand. Don’t take any chances. If you are worried about the coolant in your vehicle you can use propylene glycol coolant. Toyota only recommends ethylene and I personally do not know how PG will affect your Toyota. PG is harder to find but can be special ordered at an auto parts store.
2) Disconnect your transmission cooler lines (if you still have them connected) and let the ATF drain. I had already bypassed the radiator as you can see.
3) Remove two clips holding the front passenger wheel well splash guard in place. Now look through the wheel well to the engine and you can see the engine drain plug (5VZ-FE). Slide your 5/16" tubing over the drain and run it down to your bucket. With about 18" of extension bars and a 14mm socket you can reach the drain plug bolt located just above the drain. Loosen that up until you see coolant flowing through the tubing. If the socket is slipping off the bolt head push the extension bars up against the underside of the upper control arm. That's probably the straightest shot at the bolt head. This shows the tubing already in place and the bolt you need to loosen directly above
4) Spin the stopcock on the radiator and let the coolant flow into a bucket that can hold at least a few gallons.
5)
Remove the grille
6) Remove the 4 bolts holding the fan shroud in place. Ratchet and 10 mm socket
7) Disconnect the line going to the radiator reservoir. See step 12 for picture
8) Completely disconnect the upper radiator hose (from the radiator and engine). Vice grips are great here or use a pliers. Squeeze the clips and slide them back. My mechanic put my hoses in the wrong spot and backwards when he did the timing belt. I think I have it right in step 14.
9) Completely disconnect the lower radiator hose (from the radiator and engine). Some coolant came out once disconnected from the radiator so have your bucket ready. Stuff a towel/cloth into the engine where the lower hose was connected. Coolant was slowly leaking out of there while I was working.
10) Remove the 4 bolts holding the radiator in place.
11) Remove the radiator and tip it over your bucket to get out any remaining coolant
12) Install the new radiator. I bought mine on
Amazon.com found here. Manufacturer listed was TYC but they shipped me a Koyo radiator. There is a tab near the top on each side of the radiator (just below the upper mounting bolts). These tabs will hook into the frame and hold the radiator in place while you put your four bolts back in. Tighten down the four bolts to 8.7ft/lbs
13) You might as well clean out the radiator reservoir (in front of the battery). Remove the bracket holding the battery in place (12mm socket). Then all you have to do is lift the reservoir directly up. Mine was locked into place pretty good and took some force to pop loose. Clean out the reservoir and also shoot some water through the hose line going from the radiator to the reservoir.
14) Put the reservoir back into place, hook the reservoir, atf, and coolant hoses back up. Bolt the fan shroud back into place (couldn’t find a torque spec on those). Put the grille back on.
15) A little over 2 gallons drained out of the old radiator. I went with a 50/50 water/coolant mix. Don’t pour too fast otherwise it will just spill over.
16) Start up the car (radiator cap off) and check for any leaks. Also watch the coolant level drop in the radiator. I added more of the leftover water while the car was running. After the level stops dropping and the radiator is full, turn off the car and then add 50/50 water/coolant to the radiator reservoir. Put the radiator cap back on. At this point everything should be back together unless I forgot something here.
17) After driving around recheck your reservoir and add more water/coolant if needed.
18) Put your old coolant into some closed containers and dispose of at a recycle center.
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