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Toyota 22R and 22R-E engine factory workshop and repair manual

Goal: Replace and understand the radiator on a Toyota 22R / 22R‑E. Below is a beginner‑friendly, step‑by‑step guide, full descriptions of parts, system theory, common failures, safety, and post‑install checks. No fluff.

Safety first
- Work only on a cold engine. Hot coolant can scald.
- Wear eye protection and gloves. Catch coolant — it’s toxic to pets.
- Disconnect the negative battery terminal if you will be removing electrical connectors or the fan shroud.
- Have a drain pan, rags, and a way to dispose of coolant legally.

Basic cooling‑system theory (analogy)
- The engine is a furnace producing heat. Coolant is the water that carries that heat away, pumped by the water pump through passages in the engine. The radiator is like a heat exchanger or household radiator: coolant flows through many thin tubes and fins; air flowing across them takes the heat away. The thermostat is a temperature‑controlled valve that keeps the engine at its optimum operating temperature by controlling flow to the radiator. Fans and the shroud force air across the radiator when the vehicle is slow or stopped.

Major components — what they are and what they do
- Radiator core: rows of thin tubes and fins where coolant gives up heat to passing air.
- Radiator tanks/end caps: plastic or metal sections on the core ends that collect coolant entering/exiting the core.
- Inlet (upper) hose: connects engine outlet (hot coolant) to the top of radiator.
- Outlet (lower) hose: connects bottom of radiator back to water pump (cold coolant return).
- Radiator cap and filler neck: maintains system pressure; allows overflow to expansion tank and prevents boiling.
- Overflow/expansion tank: captures excess coolant and returns it as system cools.
- Radiator drain petcock: valve at bottom of radiator to drain coolant.
- Mechanical fan & fan clutch (on many 22R/22R‑E): pulls air through the radiator; clutch engages as needed. Some models may have electric fan(s) and temperature switch(s).
- Fan shroud: directs air through the core so the fan moves air across it efficiently.
- Transmission cooler lines (if automatic transmission): internal passages in radiator cool transmission fluid; hoses/metal lines connect to transmission.
- Thermostat: a spring‑loaded valve in the engine that opens at a set temp (about 180–195°F typical) letting coolant go to the radiator.
- Water pump: driven by the belt; circulates coolant through engine and radiator.
- Heater hoses and heater core: split from the cooling loop to heat the cabin.

Why radiators fail / why you might replace one
- Leaks: corrosion (electrolysis), cracked plastic tanks, seam failure, or punctures from road debris.
- Internal clogging: scale, rust, or plugged fins restrict flow; radiator can’t dump heat.
- Damaged fins: reduces heat transfer.
- Internal transmission cooler leaks: ATF mixing with coolant or coolant leaking into transmission.
- Age/thermal cycling: plastic tanks eventually crack where they bolt to the core.

What can go wrong (common problems and consequences)
- Air pockets after refill — cause overheating and heater failure.
- Cross‑contamination (ATF + coolant) if trans cooler leaks — costly damage.
- Fan damage or shroud misalignment — reduced cooling efficiency.
- Not replacing worn hoses/clamps — leaks after install.
- Incorrect torque or cross‑threading sensors/lines — stripped threads or leaks.
- Overfilling or using wrong coolant mix — boiling/poor corrosion protection.

Tools & supplies (typical)
- Basic metric sockets and wrenches, screwdrivers, pliers
- Line wrench for transmission cooler lines (if present)
- Drain pan
- New radiator (ensure correct part for 22R or 22R‑E)
- New upper & lower hoses and clamps (recommend replacing)
- New thermostat and gasket (strongly recommended while cooling system open)
- Coolant (50:50 ethylene glycol/water unless Toyota specifies otherwise)
- Radiator cap (if old or suspect) and new O‑rings for trans lines
- Shop towels, funnel, pressure tester (optional but recommended)
- Fan clutch wrench or a second wrench to hold water‑pump pulley (if required)
- Torque wrench and torque specs from service manual (recommended)

Step‑by‑step radiator replacement (general for 22R / 22R‑E)
1. Preparation
- Park level, engine cold. Remove negative battery terminal if you will disconnect fan wiring.
- Place drain pan under radiator petcock.

2. Drain coolant
- Open radiator cap (cold only) and open drain petcock at bottom. Also remove block drain plugs if you want a full drain.
- Catch and dispose of coolant properly.

3. Remove accessory belts / fan
- Loosen belt tensioner and remove belt from water‑pump pulley.
- Remove fan and fan clutch assembly: there’s a large nut holding the fan to the water‑pump hub. Use the correct wrench or hold the water‑pump pulley while loosening. Place fan/clutch aside. If electric fan, unplug connector and remove fan bolts.
- Remove fan shroud: unbolt top and bottom retainers and lift clear. Note shroud orientation for reinstallation.

4. Disconnect hoses and lines
- Loosen hose clamps on upper and lower radiator hoses and slide off. Remove heater hoses if needed for clearance.
- If your vehicle has A/T cooler lines, use a line wrench to disconnect them and cap lines to avoid spillage. Replace O‑rings on reconnection.
- Remove any sensor or switch (coolant temp sensor) from radiator if equipped.

5. Unbolt the radiator
- Remove top mounting bolts/clips and any side supports. Some radiators have two bolts or rubber cushions.
- Carefully lift radiator out of car. Tilt to clear lower supports and avoid snagging transmission cooler lines.

6. Inspect & prepare
- Check surrounding components: water pump (leaks), thermostat housing, hoses, belt condition, fan clutch play, heater hoses, and shroud for damage. Replace worn parts.
- If replacing thermostat, do it now (thermostat is typically in the thermostat housing on the engine). Clean mating surfaces and install new gasket.

7. Install new radiator
- Fit radiator into place, seat bottom tabs, then bolt the top mounts snug.
- Reconnect transmission cooler lines with new O‑rings lightly coated with clean coolant or oil, tighten securely.
- Reattach heater hoses, upper and lower hoses with new clamps. Position clamps properly (over reinforcement bead on hoses).
- Reinstall fan shroud and fan assembly. Refit drive belt and set belt tension per spec.

8. Refill and bleed
- With radiator cap off, slowly fill with 50/50 coolant until full.
- Start engine with heater set to HOT and blower on high. Let idle; as engine warms the thermostat will open and coolant level will drop — top up as needed. Watch for air bubbles — that’s the trapped air escaping. Squeeze upper hoses to help dislodge air.
- When coolant level steady and no large bubbles, install radiator cap. Run to operating temp and verify temperature gauge behavior.
- If available, use a hand pressure tester to pressure‑test the system (pump to ~15 psi) and check for leaks.

9. Final checks
- Check for leaks around hoses, petcock, trans lines, and fittings.
- Recheck coolant level after a short drive and again after 24 hours (air can be trapped and work its way out).
- Dispose of old coolant and parts properly.

Tips and troubleshooting
- Replace thermostat and both radiator hoses while you’re in there — cheap insurance.
- If the engine continues to overheat: verify thermostat opening, confirm fan operation, pressure test for leaks, and ensure water pump is pumping (no shaft play, no leaked coolant).
- If the heater works intermittently or there’s overheating with low coolant, you probably have trapped air — bleed again.
- Bent or blocked fins: use compressed air gently from the engine side outward. Do not push debris into the core.
- If transmission fluid is contaminated with coolant (or vice versa), don’t just refill — flush and service both systems. That may require a new radiator and transmission fluid change.

Final notes
- Radiator replacement is moderately straightforward but requires attention to bleeding the system and properly handling trans cooler lines.
- When in doubt about torque values or specific clips/fasteners unique to your year/model, consult a factory service manual for that 22R or 22R‑E variant.

This gives you the what, why, and how — follow safety and bleeding steps carefully and replace hoses/thermostat while the system is open.
rteeqp73

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