REMOVAL & INSTALLATION
See Figures 1 through 12
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
- Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.
- If necessary, remove the engine undercover.
- Drain the engine coolant into a suitable container.
- On Canadian models, remove the two bolts and the Daytime Running Lamp (DRL) relay box.
- Disconnect the electric cooling fan wiring.
- Disconnect the upper radiator hose.
- Separate the lower hose from the water inlet pipe.
- Disconnect the coolant reservoir hose.
- If the vehicle is equipped with automatic transmission, disconnect the oil cooler hoses.
- Disconnect the No. 1 cooling fan connector and wire clamp. If equipped with A/C, disconnect the No. 2 cooling fan connector.
- Remove the oxygen sensor wire clamps.
- Remove the two upper radiator support bolts and the two supports.
- Lift out the radiator assembly being careful not to damage the radiator. Remove the lower radiator supports.
- If necessary, remove the four bolts and the No. 1 cooling fan. On A/C models, remove the three bolts and the No. 2 cooling fan.
- Install the No. 2 cooling fan to the radiator with the three bolts and torque them to 43 inch lbs. (5 Nm).
- Install the No. 1 cooling fan to the radiator with the four bolts and torque them to 43 inch lbs. (5 Nm).
- Install the radiator lower supports and carefully lower the radiator assembly into position.
- Install the two upper radiator supports with the support bolts. Tighten the support bolts to 9 ft. lbs. (12 Nm). Make sure that the rubber cushions are not distorted.
- If detached, connect the No. 1 cooling fan connector and the wire clamp.
- If equipped with A/C, connect the No. 2 cooling fan wiring.
- On the Celica, connect the two oxygen sensor wire clamps.
- If the vehicle is equipped with automatic transmission, connect the oil cooler lines.
- Connect the coolant reservoir hose.
- Attach the lower radiator hose to the water inlet pipe.
- Connect the upper radiator hose.
- Connect the electric cooling fan electrical wiring.
- Install the DRL relay box and secure it with the two mounting bolts.
- If removed, install the battery tray, battery and clamp to the engine compartment.
- Connect the negative battery cable.
- Refill the cooling system with coolant and bleed the system. Check the cooling system for leaks and proper operation.
- If the system is OK, install the engine undercover if removed.