Precautions Perform a radiator replacement ONLY when the engine is completely cool and not running. For safety wait several hours (or overnight) for the engine to cool. Inspect your hoses carefully and replace them if needed. Depending on the age of your vehicle this might be a prudent step. Removal 1) REMOVE THE ENGINE UNDER COVER/SKID PLATE Remove the 4 or 5 bolts holding the skid plate on and remove the skid plate. 2) DRAIN THE ENGINE COOLANT Loosen the radiator cap and place a catch pan below the radiator drain plug and loosen the plug to drain the radiator. 3) DISCONNECT THE RADIATOR RESERVOIR HOSE FROM THE RADIATOR This is the small hose at the top of the radiator connecting to the white overflow/fill tank. 4) DISCONNECT THE UPPER AND LOWER RADIATOR HOSES FROM THE RADIATOR Using pliers, squeeze the pinch clamps on the upper and lower radiator hoses and remove the hoses. 5) DISCONNECT THE AUTOMATIC TRANSMISSION (A/T) OIL COOLER HOSES FROM THE RADIATOR On the bottom of the radiator disconnect the 2 smaller lines which are the automatic transmission cooler lines. Keep in mind the fluid in these is AT fluid, not coolant so you may want to use a separate catch pan for any dripping. There should only be a few drops of fluid that leak out of these. 6) REMOVE THE LOWER FAN SHROUD There are 2 small clips that hold a semi-circular piece on the fan shroud, removing these allows you to pull the radiator straight up and out of the engine compartment. Save the clips for re-install later. 7) REMOVE THE MAIN FAN SHROUD Once the radiator assembly is removed you can remove the fan shroud by removing the 4 bolts holding it on to the radiator. These will be reused for installing on the new radiator. 8) REMOVE THE RADIATOR ASSEMBLY There are 4 bolts holding the radiator in place which need to be removed. There are also 2 tabs that hold the radiator in place so you can remove the 4 bolts without the radiator dropping out. Once the bolts are removed you can lift the entire radiator assembly straight up and out of the engine compartment, being careful to not hit the fan or snag any of the loose hoses. Reinstallation And Refill 1) INSTALL THE MAIN FAN SHROUD ON NEW RADIATOR Using the 4 bolts, install the main shroud on the new radiator. 2) INSTALL RADIATOR ASSEMBLY BACK INTO VEHICLE Carefully lower the new radiator into the engine compartment and set the bracket tabs back into the support holes. Be careful not hit the new radiator surface on anything. Install the 4 bolts. 3) INSTALL THE LOWER FAN SHROUD Replace the lower shroud with the clips. 4) CONNECT AUTOMATIC TRANS (A/T) COOLER HOSES 5) CONNECT LOWER AND UPPER RADIATOR HOSES 6) CONNECT RADIATOR RESERVOIR HOSE 7) FILL ENGINE WITH COOLANT Toyota recommends using only Toyota Super Long Life 50/50 Coolant (red stuff) which can be found at your dealership or online (see Amazon links here). At about $25/gallon it's not cheap but should last a long time. My new radiator took just a little over 1 gallon to refill it (if your old coolant is in decent shape and you're careful about catching it in your drain pan you can reuse a small amount of it to top off the radiator and thus do not have to buy 2 gallons). 8) START ENGINE AND CHECK FOR LEAKS Re-check the coolant level and adjust if necessary 9) INSTALL THE ENGINE UNDER COVER/SKID PLATE
