Toyota 16400-22070
Radiator Assembly

One must begin radiator replacement by uninstalling the upper front fender apron seal and upper radiator support seal after draining the engine coolant while also removing the bumper cover. The radiator removal starts with the air pump assembly followed by air cleaner and engine coolant reservoir by disconnecting the 3 radiator reservoir hoses and removing the bolt for the 2ZZ-GE. The first step in removing the radiator demands disconnecting the No. 1 and No. 2 electric cooling fan connectors and the upper and lower radiator hoses and 2 A/T oil cooler hoses. Disconnect the hood lock by removing 3 bolts while also taking away the 2 bolts with the center brace, followed by 2 bolts, 2 nuts, and 2 condenser upper supports, and finally removing the bolt needed for cruise control actuator disconnection when installed. Begin the uninstallation by removing 2 radiator upper support bolts, proceeding to take away 2 upper radiator support bushings before successfully extracting the radiator assembly with both lower radiator support bushings. The removal of the electric cooling fan from the radiator requires disassembly of its 2 bolts together with its associated cooling fan assembly. Install the electric cooling fan to the radiator with its 2 bolts at 5.0 Nm (51 kgf-cm, 44 inch lbs.), then position the lower radiator support bushings before setting the radiator assembly followed by upper radiator support bushings and radiator upper support with its 2 bolts. Processing with cruise control demands installation of the cruise control actuator using 3 bolts followed by 2 condenser upper supports and the 2 bolts and nuts, center brace using 2 bolts, and hood lock accompanied by 3 bolts. Connect the two A/T oil cooler hoses with the lower radiator hose and the upper radiator hose and both No. 1 and No. 2 electric cooling fan connectors. The engine coolant reservoir gets secured through its bolt at 5.0 Nm torque (51 kgf-cm and 44 inch lbs) before connecting the three radiator reservoir hoses. Place the air cleaner and after that install the 2ZZ-GE air pump assembly before putting on the bumper cover. After filling the system with coolant workers must connect the upper front fender apron seal and upper radiator support seal before starting the vehicle to identify cooling system leakages.

The vehicle radiator cleaning process begins with blocking fin inspection followed by water or steam cleaning for clogged fins then compressed air drying while keeping a safe distance from fins to prevent damage. The straightening of distorted fins requires using a screwdriver or pliers alongside caution against exposing electronic parts to moisture.

Wash them with water or a steam cleaner and dry with compressed air.

Tighten the drain plug, install the engine coolant reservoir, plug the inlet and outlet pipes with Special Service Tool, apply a test pressure of 177 kPa (1.8 kgf/cm2, 26 psi), and submerge the radiator in water.

Torque the cooler pipe to 14.7 Nm (150 kgf-cm, 11 ft. lbs.).

Inspect the lock plate for damage, correcting any deformation to avoid reassembly issues.

Disconnect the No. 1 and No. 2 electric cooling fan connectors, the upper and lower radiator hoses, and the 2 A/T oil cooler hoses.

Remove the drain plug and O-ring, then assemble Special Service Tool: 0923-01010, adjusting the stopper bolts to ensure dimension "B" is 0.2 - 0.3 mm (0.008 - 0.012 inch).