Toyota Yaris: Radiator / Installation

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (cooling) / Radiator / Installation

INSTALLATION

PROCEDURE

1. INSTALL RADIATOR DRAIN COCK PLUG

(a) Install the O-ring to the radiator drain cock plug.

NOTICE:

Replace the O-ring if it is damaged.

(b) Install the radiator drain cock plug.

2. INSTALL LOWER RADIATOR SUPPORT

(a) Install the 2 lower radiator supports to the radiator assembly.

3. INSTALL RADIATOR SUPPORT CUSHION

(a) Install the 2 radiator support cushions to the radiator assembly.

4. INSTALL RADIATOR ASSEMBLY

(a) Engage the 2 claws and 2 guides to install the fan shroud to the radiator assembly.

NOTICE:

Do not damage the radiator assembly when installing the fan shroud.

(b) Install the radiator assembly together with the fan shroud to the vehicle body.

NOTICE:

Do not apply excessive force to the cooler condenser assembly or pipe when installing the radiator assembly with the fan with motor assembly.

5. INSTALL INTERCOOLER ASSEMBLY

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6. CONNECT NO. 3 AIR HOSE

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7. CONNECT NO. 4 AIR HOSE

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8. INSTALL COOLER CONDENSER ASSEMBLY

(a) Engage the guide to install the cooler condenser assembly.

NOTICE:

Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

(b) Install the 3 bolts.

9. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

10. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.

11. CONNECT NO. 3 WATER BY-PASS HOSE

(a) Connect the No. 3 water by-pass hose to the radiator assembly and slide the clip to secure it.

12. CONNECT WATER BY-PASS HOSE

(a) Connect the water by-pass hose to the radiator assembly and slide the clip to secure it.

(b) Engage the clamp.

13. INSTALL NO. 1 RADIATOR AIR GUIDE LH

(a) Engage the claw and 2 guide to install the No. 1 radiator air guide LH.

(b) Engage the 2 clamps and connect the wire harness.

14. INSTALL NO. 1 RADIATOR AIR GUIDE RH

(a) Engage the claw and 2 guide to install the No. 1 radiator air guide RH.

15. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE LH

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16. INSTALL FRONT RADIATOR SIDE AIR GUIDE PLATE RH

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17. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

(a) Install the upper front radiator support with the 4 bolts.

Torque:

7.1 N·m {72 kgf·cm, 63 in·lbf}

(b) Engage the clamp and connect the No. 3 water by-pass hose.

(c) Engage the 3 clamps and connect the wire harness.

(d) Engage the 3 clamps and connect the wire harness.

(e) Connect the horn connector.

(f) Engage the clamp and connect the wire harness.

(g) Connect the hood lock control cable assembly.

(h) Connect the 2 airbag connectors.

NOTICE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

HINT:

Refer to How to Connect or Disconnect Airbag Connector:

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18. INSTALL HOOD LOCK ASSEMBLY

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19. INSTALL FRONT BUMPER REINFORCEMENT

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20. INSTALL COOL AIR INTAKE DUCT

(a) Install the cool air intake duct with 3 clips.

21. INSTALL FRONT BUMPER ENERGY ABSORBER

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22. INSTALL RADIATOR UPPER AIR GUIDE PLATE

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23. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No. 1 air cleaner inlet with 2 clips.

24. INSTALL NO. 3 AIR CLEANER INLET

(a) Engage the 2 claws to install the No. 3 air cleaner inlet.

25. INSTALL HEADLIGHT ASSEMBLY LH

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26. INSTALL HEADLIGHT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

27. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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28. ADD ENGINE COOLANT

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29. INSPECT FOR COOLANT LEAK

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30. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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31. INSPECT SRS WARNING LIGHT

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32. INSPECT HOOD SUB-ASSEMBLY

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33. ADJUST HOOD LOCK ASSEMBLY

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34. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

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