Toyota 16400-0H210
Radiator Assembly

The radiator installation process starts by attaching the two radiator support lowers to the assembly before adding the two support cushions. When installing the fan assembly with motor to the radiator make sure the 2 guides located at the bottom match up with the 3 snap fits on top. After attaching the radiator to the body it is necessary to tighten the condenser assembly with 4 bolts at 5.4 Nm (55 kgf-cm, 48 in-lbf). Seam the underlying connectors of the fan motors and then fasten the three clamps. Follow this by attaching the hood lock control cable assembly with its clamp and then proceeding to install the hood lock assembly that requires 3 bolts to be torqued to 7.5 Nm (77 kgf-cm, 66 in-lbf). Next, connect the horn connector. First install the oil cooler outlet and inlet hoses to the radiator assembly and after that connect both the radiator hose outlet and inlet and finally attach the radiator reservoir tank hose. The service technician should mount the front bumper energy absorber followed by installing the front bumper assembly either with or without fog light before mounting the air cleaner inlet assembly alongside the air cleaner cap sub-assembly. End the process by filling the vehicle with engine coolant followed by a leak inspection and installation of both engine under covers LH and RH and front wheel opening extension pads on both sides.

Before radiator replacement start by taking out the drain plug together with its O-ring. Place the claw to the handle's overhaul position by inserting it through hole A. Then utilize Special Service Tool: 09231-01010, 09230-01010, 09231-01030 to adjust the stopper bolt to maintain dimension B between 0.2 to 0.3 mm (0.008 to 0.012 in.) and avoid claw harm. Release the caulking through the special service tool until the handle stops by the stopper bolt. A soft-faced hammer used to gently strike the bracket of the radiator or the radiator hose inlet or outlet will detach the tank and allow O-ring removal. When working on the radiator tank lower component of an automatic transaxle remove the bolt as well as 2 clips and hose from the radiator assembly by following the same upper tank removal approach. You should begin by taking out the screw and cooler pipe (A) followed by the nut combined with a plate washer (B) before extracting the oil cooler (C) and its two O-rings (D) from the oil cooler. The tank removal method for the radiator lower component remains the same in manual transaxle systems as it does in upper tank procedures.

Attach the punch assembly to the overhaul handle, inserting it into the hole in part A.

Attach the fan assembly with motor to the radiator using the 2 guides at the bottom and 3 snap fits on the top.

Reinstall the air cleaner inlet assembly and the air cleaner cap sub-assembly, add engine coolant, check for leaks, and then reinstall the engine under covers and front wheel opening extension pads on both sides.