Radiator installation (4JJ3 with DPD)

1. Component views

Radiator

Part name

  1. Fan guide
  2. Radiator reserve tank
  3. Bolt
  4. Radiator upper hose
  5. Bolt
  6. Radiator
  7. Radiator reserve tank hose
  8. Drain plug
  9. Radiator lower hose
  10. Bolt
  11. Fan shroud

Tightening torque

3: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

5: 24.7 N・m { 2.5 kgf・m / 18 lb・ft }

10: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2. Radiator installation

1) Install the radiator to vehicle.

Tightening torque: 24.7 N・m { 2.5 kgf・m / 18 lb・ft }

Caution

  • Do not damage the radiator core with the fan blade.

2) Connect the condenser to the radiator.

Caution

  • Do not apply a load on the A/C pipe and hose.

Tightening torque: 6.6 N・m { 0.7 kgf・m / 58 lb・in } Upper side bolt

Tightening torque: 5.9 N・m { 0.6 kgf・m / 52 lb・in } Lower side bolt

Legend

  1. Condenser
  2. Mounting bolt
  3. Radiator
  4. Pin section

3. Intercooler installation

1) Install the intercooler to the frame.

Tightening torque: 20.1 N・m { 2.0 kgf・m / 15 lb・ft }

2) Connect the intake hose to the intercooler.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

3) Connect the air intake hose to the intercooler.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

Legend

  1. Air intake hose
  2. Clamp
  3. Intercooler
  4. Clamp
  5. Intake hose

4. Radiator lower hose connect

1) Connect the radiator lower hose and clamp to the water intake pipe.

Note

  • Insert the lower hose until it makes full contact with the pipe.
  • Soapy water can be applied when installing the lower hose.

Legend

  1. Clamp
  2. Arrow mark

Note

  • Align the clamp with the lower hose arrow mark end to install.

Legend

  1. Clamp
  2. Arrow mark
  3. Radiator lower hose

Note

  • Install the clamp in the direction shown in the following diagram.
  • The diagram about the clamp direction shows the state viewed from the vehicle front.

5. Fan guide installation

1) Install the fan guide to the radiator.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

6. Radiator upper hose installation

1) Install the radiator upper hose and clamp to the thermostat and radiator.

Note

  • Align the painted arrow on the upper hose with the pipe boss section to install.
  • Insert the upper hose until it makes full contact with the pipe.
  • Soapy water can be applied when installing the upper hose.

Legend

  1. Radiator upper hose
  2. Boss section
  3. Clamp
  4. Arrow mark

Note

  • Align the clamp with the upper hose arrow mark end to install.

Legend

  1. Clamp
  2. Arrow mark

Note

  • Install the clamp in the direction shown in the following diagram.
  • The diagram about the clamp direction shows the state viewed from the vehicle front.

7. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note

  • Wash with clean water, and drain the water.

2) Assemble the reserve tank hose to the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. Reserve tank hose

3) Install the radiator reserve tank to the fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

4) Connect the radiator reserve tank hose to the radiator.

Caution

  • Assemble the reserve tank hose to the dent to fit the radiator reserve tank shape.

8. Engine cover installation

1) Install the engine cover to the engine.

Legend

  1. Engine cover

9. Front bumper impact support installation

1) Install the front end engine hood stay to the frame.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Legend

  1. front end engine hood stay

2) Install the front bumper impact support to the vehicle.

Tightening torque: 8.9 N・m { 0.9 kgf・m / 79 lb・in }

Legend

  1. Front bumper impact support

3) Install the headlight fixing bolt to the front bumper impact support.

Tightening torque: 8.5 N・m { 0.9 kgf・m / 75 lb・in }

10. Front bumper impact bar installation

1) Install the air guide to the radiator lower support.

Legend

  1. Air guide

2) Install the support bracket to the frame.

Legend

  1. Support bracket

3) Install the front bumper impact bar to the frame.

Tightening torque: 62 N・m { 6.3 kgf・m / 46 lb・ft }

Legend

  1. Front bumper impact bar

4) Install the air guide to the front bumper impact support.

Legend

  1. Air guide

11. Charge air cooler temperature sensor 1 installation

1) Install charge air cooler temperature sensor 1 to the intercooler.

Tightening torque: 14 N・m { 1.4 kgf・m / 124 lb・in }

Legend

  1. Charge air cooler temperature sensor 1
  2. Intercooler

2) Connect the connector to charge air cooler temperature sensor 1.

12. Front bumper installation

1) Install the front bumper to the vehicle.

Legend

  1. Front bumper
  2. Clip

2) Install the front bumper support to vehicle.

3) Install the soft nose to the front bumper support.

Legend

  1. Clip
  2. Screw
  3. Soft nose
  4. Front bumper support

4) Connect the connector to the front bumper.

5) Install the intake air duct to the air cleaner box and radiator core support.

Legend

  1. Intake air duct
  2. Clip

13. Inner liner installation

1) Install the inner liner to the front fender panel.

14. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

15. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

16. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

  • Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.

Note

  • Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.

Caution

  • Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. MAX line
  3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution

  • Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note

  • If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note

  • Touch the radiator upper hose, and confirm that it has become warm.
  • If it has not become warm, go back to Step 11.

Caution

  • Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution

  • If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
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