Radiator - Removal, Inspection and Installation

Removal Note! If you have decided to remove the radiator because of a leak, be aware that small leaks can often be repaired without removing the radiator by using a special radiator sealant.

· First, disconnect the negative battery cable. If necessary to improve access, place wheel chocks behind the rear wheels, raise the front of the vehicle with a jack and support it on stands. Remove the splash shields from under the engine compartment.

· Drain the coolant.

· Disconnect the upper and lower hoses from the radiator.

Fig. 3.3.1. Disconnecting the Upper and Lower Radiator Hoses

· Disconnect the reserve tank hose from the radiator filler neck. · On 3S-FE engines, disconnect the wiring from the fan switch on the lower radiator tank.

· Remove the fan with shroud.

· On models with automatic transmission, disconnect the fluid cooler lines at the bottom of the radiator.

· Remove the bolts securing the upper brackets to the engine compartment cross member. · Lift the radiator off the lower rubber mounts and remove it from the engine compartment.

· If necessary, remove the rubber mounts.

Inspection

If the radiator was removed due to suspected clogging, flush it in the reverse direction. Clean dirt and debris from the radiator fins using compressed air or a soft brush. When using compressed air, protect your eyes. Be careful, as the radiator fins are sharp.

If necessary, have a radiator specialist perform a special inspection to determine whether there is internal blockage.

A leaking radiator must be repaired by a specialist. Do not attempt to repair leaks by welding or soldering, as this may damage the plastic components of the radiator.

As a last resort, minor leaks can be sealed without removing the radiator from the vehicle, using a radiator sealant in accordance with the manufacturer's instructions.

If the radiator must be repaired or replaced, first disconnect all hoses. Inspect the condition of the upper and lower radiator rubber mounts and replace them if necessary.

Installation

Installation is performed in the reverse order of removal. Finally, fill the system with coolant.