Toyota 16400-21071
Radiator Assembly

Measure the valve opening pressure on the radiator cap sub-assembly when performing inspection and cleaning of the radiator. The inspection of rubber packing numbers 1, 2 and 3 requires water cleaning with hand scouring when foreign objects or stains are detected. The inspection should show that parts 1, 2, or 3 have no deformities, cracks or swelling and that 3 and 4 are freely separate from each other. Before testing with the radiator cap machine apply engine coolant to 2 and 3 then operate the pump several times with the device oriented at 30 degrees or more above horizontal while observing maximum pressure. The radiator cap sub-assembly needs replacement when the maximum pressure measurement falls below the specified minimum standard value. On-vehicle cleaning requires checking fins for blockage by inspecting for leaves or dirt along with insects or inspecting the hose connections and ensuring the radiator and condenser are clean. The blockage removal process begins by washing the fins with water or using a steam cleaner but you must maintain distance to prevent damage from occurring. To straighten fins you should use both a screwdriver and pliers while refraining from pouring water toward electronic elements. After cleaning, the fins need to be dried using compressed air.

A radiator replacement process starts with disconnecting the negative battery terminal cable and allowing at least 90 seconds of wait time to activate Air Bag and seat belt pretensioners. Engine coolant drainage is necessary before disconnecting three hoses which include the radiator's inlet and outlet and automatic transaxle oil cooler inlet and outlet. The radiator grille and hood lock assembly require removal of 3 bolts to begin. Additionally the hood lock support sub-assembly needs detachment through removal of 2 bolts and a clip with a hood lock support. The radiator support sub-assembly upper requires removal when you disconnect two connectors from the horns, detach the condenser using two bolts and take out four bolts to remove the radiator support upper. The radiator assembly removal process requires disconnecting the cooling fan motor connector and unbolting 3 pieces for the fan shroud with fan and then unbolting 2 water filler positions and lastly removing the 2 radiator support cushions and the radiator support lower. The first step needs to be installing the radiator assembly alongside the 2 radiator support cushions and radiator support lower after which you should install the water filler with 2 bolts tightened to 7.5 Nm followed by installing the fan shroud with fan through 3 bolts of 7.5 Nm tightening torque. After installing the radiator support sub-assembly upper with 4 bolts reaching 5.0 Nm torque then you should attach the condenser through 2 bolts while connecting the 2 connectors to the horns. Begin with installing the radiator support opening cover and continuously attach the hood lock support sub-assembly with two bolts and one clip before installing the hood lock assembly temporarily using three bolts. After adjusting the hood lock assembly you should install the radiator grille. Install first the automatic transaxle oil cooler hoses between outlet and inlet and then position the radiator hose tubing between outlet and inlet. A procedure includes reconnecting the cable to the negative terminal followed by inserting engine coolant while checking for leaks and performing required initializations following negative terminal cable changes.

You must verify the radiator cap sub-assembly through valve opening pressure measurement when checking and cleaning the radiator. Clean rubber packing 1, 2 and 3 by washing them with water followed by a manual scour. Ensure rubber packing in positions 1, 2, or 3 exhibits no deformity, cracking or swelling and parts 3 and 4 are not fused together. Engine coolant needs application to rubber packing 2 and 3 prior to using a radiator cap tester. The cap tester should be pumped multiple times in a position above horizontal at 30° or higher to identify the maximum pressure performance but the cap's inability to reach this point does not indicate failure. The replacement of a radiator cap sub-assembly becomes necessary when maximum pressure readings fall short of the minimum standard values. Vehicle cleaning should focus on clearing radiator and condenser blockages while ensuring these components remain free from leaves and dirt and insects together with cleaning the hose connections. Water or a sterile steam cleaner can be used to wash blocked fins when using proper standard distance during injection to prevent fin damage. Use a screwdriver or pliers to adjust bent fins and avoid spraying water toward electronic elements. Dry the fins with compressed air as the last step.

Begin radiator cleaning by inspecting the fins for blockage because water washing or steam cleaning along with compressed air drying will resolve obstructions if detected. Steaming between the device and core fins should be done carefully to protect the radiator fins from damage. Straightening damaged fins is possible through use of a screwdriver or pliers. Routine cleaning operations must exclude direct water exposure for electronic devices.

Remove it by taking out 2 clips.

First, drain the engine coolant.

Remove the radiator grille, hood lock assembly by taking out 3 bolts, and the hood lock support sub-assembly by removing 2 bolts, a clip, and the support.

Remove 2 clips to take off the radiator support opening cover.

Inspect the lock plate for damage and correct any deformation.

Tighten the drain plug, plug the inlet and outlet pipes with Special Service Tool: 09230-01010, apply pressure with a radiator cap tester to 177 kPa (1.8 kgf/cm2, 26 psi), and submerge the radiator in water to check for leaks.

Use 2 bolts with a torque of 7.5 Nm.

First, drain the engine coolant.

Use compressed air, ensuring to maintain a safe distance to avoid damaging the fins.

Take off the 2 nuts and 2 plate washers.

Maintain a safe distance between the steam cleaner and the core to avoid damaging the fins.

Remove the drain plug and O-ring, disconnect the No. 3 radiator hose, and remove the 2 bolts and water filter.