Toyota Prius 2002-06

Removal & Installation

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Fig. Exploded view of components removed to access the radiator and cooling fans



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Fig. Exploded view of cooling fan and radiator mounting

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove rear floor board no.2.
  4.  
  5. Remove deck floor box rear.
  6.  
  7. Remove rear floor board no.3.
  8.  
  9. Disconnect battery negative terminal.
  10.  
  11. Remove radiator support opening cover.
  12.  
  13. Remove the left engine under cover.
  14.  
  15. Remove the right engine under cover.
  16.  
  17. Drain the coolant in the radiator on the engine side.
  18.  
  19. After draining the coolant in the radiator on the engine side, remove the radiator drain cock plug.
  20.  
  21. Drain the coolant in the radiator on the hybrid side.
  22.  
  23. Remove front bumper cover.
  24.  
  25. Disconnect the radiator hoses
  26.  
  27. Disconnect the radiator reservoir tank hose.
  28.  
  29. Disconnect the inverter reservoir tank hose from the clamps.
  30.  
  31. Remove the 3 bolts and inverter bracket.
  32.  
  33. Remove the 2 bolts and cooler bracket.
  34.  
  35. Disconnect the horn connector.
  36.  
  37. Remove the 3 bolts and disconnect the hood lock control cable, then remove the hood lock assembly.
  38.  
  39. Remove the 5 bolts and radiator support.
  40.  
  41. Remove the hood lock control cable from the radiator support.
  42.  
  43. Disconnect the wire harness clamps shown in the illustration.
  44.  
  45. Remove the 4 bolts, then remove the fan with motor from the vehicle.
  46.  

To install:

  1. Set the fan with motor to the vehicle, then install it with the 4 bolts. Tighten to 7.5 Nm (66 in. lbs)
  2.  
  3. Connect the 2 wire harness clamps.
  4.  
  5. Install the hood lock control cable to the radiator support.
  6.  
  7. Install the radiator support and tighten the bolts to 5.0 Nm (44 in. lbs)
  8.  
  9. Connect the hood lock control cable to the hood lock assembly.
  10.  
  11. Install the hood lock assembly with the 3 bolts.
  12.  
  13. Connect the horn connector.
  14.  
  15. Install the cooler bracket with the 2 bolts. Tighten bolt A to 20 Nm (15 ft. lb), and bolt B to 8.5 Nm (75 in. lbs).
  16.  
  17. Install the inverter bracket with the 3 bolts.
  18.  
  19. Connect the inverter reservoir tank hose from the clamps.
  20.  
  21. Connect the radiator reservoir tank hose.
  22.  
  23. Connect the radiator hoses
  24.  
  25. Install front bumper cover.
  26.  
  27. Drain the coolant in the radiator on the hybrid side.
  28.  
  29. Install the radiator drain cock plug.
  30.  
  31. Drain the coolant in the radiator on the engine side.
  32.  
  33. Install the right engine under cover.
  34.  
  35. Install the left engine under cover.
  36.  
  37. Install radiator support opening cover.
  38.  
  39. Connect battery negative terminal.
  40.  
  41. Install rear floor board no.3.
  42.  
  43. Install deck floor box rear.
  44.  
  45. Install rear floor board no.2.
  46.  

 
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