Toyota Yaris: Radiator / Removal

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

REMOVAL

CAUTION / NOTICE / HINT

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

  • Learning completes when vehicle is driven

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    Stop and start system

    Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

  • Learning completes when vehicle is operated normally

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Power door lock control system

    • Back door opener

    Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

    -

PROCEDURE

1. PRECAUTION

NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 120 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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3. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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4. DRAIN ENGINE COOLANT

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5. REMOVE HEADLIGHT ASSEMBLY LH

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6. REMOVE HEADLIGHT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

7. REMOVE NO. 3 AIR CLEANER INLET

(a) Disengage the 2 claws to remove the No. 3 air cleaner inlet from the vehicle.

8. REMOVE NO. 1 AIR CLEANER INLET

(a) Remove the 2 clips and No. 1 air cleaner inlet from the vehicle.

9. REMOVE RADIATOR UPPER AIR GUIDE PLATE

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10. REMOVE FRONT BUMPER ENERGY ABSORBER

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11. REMOVE COOL AIR INTAKE DUCT

(a) Remove the 3 clips and cool air intake duct from the vehicle.

12. REMOVE FRONT BUMPER REINFORCEMENT

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13. REMOVE HOOD LOCK ASSEMBLY

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14. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY

(a) Disconnect the 2 airbag connectors.

NOTICE:

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

HINT:

Refer to How to Connect or Disconnect Airbag Connector:

Click here

(b) Disconnect the hood lock control cable assembly from the upper radiator support sub-assembly.

(c) Disconnect the airbag connector.

(d) Disconnect the airbag connector.

(e) Disconnect the horn connector.

(f) Disengage the 3 clamps.

(g) Disengage the clamp.

(h) Disengage the 3 clamps to disconnect the wire harness from the upper radiator support sub-assembly.

(i) Disengage the clamps to disconnect the No. 3 water by-pass hose from the upper radiator support sub-assembly.

(j) Remove the 4 bolts and upper radiator support sub-assembly from the front side member bracket sub-assembly.

15. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE LH

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16. REMOVE FRONT RADIATOR SIDE AIR GUIDE PLATE RH

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17. REMOVE NO. 1 RADIATOR AIR GUIDE LH

(a) Disengage the 2 clamps and disconnect the wire harness.

(b) Disengage the claw and 2 guides to remove the No. 1 radiator air guide LH.

18. REMOVE NO. 1 RADIATOR AIR GUIDE RH

(a) Disengage the claw and 2 guides to remove the No. 1 radiator air guide LH.

19. DISCONNECT WATER BY-PASS HOSE

(a) Disengage the clamp.

(b) Slide the clip and disconnect the water by-pass hose from the radiator assembly.

20. DISCONNECT NO. 3 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 3 water by-pass hose from the radiator assembly.

21. DISCONNECT NO. 1 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 1 radiator hose from the radiator assembly.

22. DISCONNECT NO. 2 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

23. SEPARATE COOLER CONDENSER ASSEMBLY

(a) Remove the 3 bolts.

(b) Disengage the guide to separate the cooler condenser assembly from the radiator assembly.

NOTICE:

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

24. DISCONNECT NO. 4 AIR HOSE

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25. DISCONNECT NO. 3 AIR HOSE

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26. REMOVE INTERCOOLER ASSEMBLY

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27. REMOVE RADIATOR ASSEMBLY

(a) Remove the radiator assembly together with the fan shroud from the vehicle body.

NOTICE:

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

(b) Disengage the 2 claws and 2 guides to remove the fan shroud from the radiator assembly.

NOTICE:

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

28. REMOVE RADIATOR SUPPORT CUSHION

(a) Remove the 2 radiator support cushions from the radiator assembly.

29. REMOVE LOWER RADIATOR SUPPORT

(a) Remove the 2 lower radiator supports from the radiator assembly.

30. REMOVE RADIATOR DRAIN COCK PLUG

(a) Remove the radiator drain cock plug.

(b) Remove the O-ring from the radiator drain cock plug.

    On-vehicle Inspection

    ON-VEHICLE INSPECTION PROCEDURE 1. INSPECT RESERVE TANK CAP CAUTION: Do not remove the reserve tank cap and air release valve while the engine and radiator assembly are still hot...

    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...

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