Tools & supplies
- Metric socket set (8, 10, 12, 14 mm commonly), 1/4" & 3/8" ratchets + extensions
- Combination wrenches (8–14 mm)
- Flat and Phillips screwdrivers
- Pliers (slip-joint + spring-clip/side-cutting)
- Hose clamp pliers or large pliers for spring clamps
- Drain pan (capacity 5–10 L)
- Funnel, fresh 50/50 antifreeze/distilled water or OEM premix
- New radiator (vehicle-specific), new radiator cap (recommended)
- New upper & lower radiator hoses (recommended) and new clamps (worm-drive or OEM spring clamps)
- New thermostat & gasket (highly recommended)
- RTV or OEM O‑ring(s) for sensor housings as required
- Torque wrench (for critical bolts)
- Plastic trim tools (if removing bumper/grille)
- Shop rags, gloves, safety glasses
- Jack & axle stands or ramps (if needed for access)
- Small brass/nylon pick for O‑rings
- Coolant-safe sealant (if service manual calls for it)
- Waste coolant container/bottle for disposal per local codes

Safety & prep
- Work on a cool engine. Never open radiator cap with hot engine — severe scald risk.
- Wear eye protection and gloves. Antifreeze is toxic — contain and dispose properly.
- Disconnect negative battery terminal if you will be working near fan motors/electrical connectors or removing fan assembly.
- Park on level ground, set parking brake. Support vehicle if underbody access is needed.
- Have a clear, organized workspace and a marker to label hoses/electrical connectors.

Step‑by‑step procedure (generic Toyota chassis/body; consult vehicle service manual for model-specific details and torque specs)

1. Warm engine, then cool:
- Briefly run engine to warm coolant (this makes draining easier), then shut off and let cool until lukewarm.

2. Relieve system pressure and drain coolant:
- With engine cold, remove radiator cap.
- Place drain pan under radiator drain petcock/drain plug (lower radiator hose if no petcock).
- Open petcock or loosen lower hose clamp at radiator outlet and drain into pan. Remove upper cap or expansion tank cap to speed flow.

3. Remove front aerodynamics or grille as required:
- Remove bumper/grille/plastic covers only as needed to access the top radiator mounts, fan shroud or hose connections. Use trim tools to avoid breaking clips.

4. Disconnect electrical and peripheral fittings:
- Unplug fan connector(s), engine coolant temperature sensor(s) on radiator/transmission lines, and electric fan connectors.
- If vehicle has A/C condenser mounted to radiator and removal requires moving condenser, support it and do NOT discharge refrigerant. If condenser removal is required beyond simple movement, have A/C service performed by certified tech.

5. Remove fan & shroud assembly:
- For electric fan(s): remove shroud mounting bolts and lift fan/shroud out as an assembly. Use sockets or screwdrivers as needed.
- For mechanical fan/fan clutch: remove fan clutch or separate fan from water pump pulley (loosen water pump pulley bolts or remove fan clutch nut). Hold water pump pulley with appropriate tool and use large socket for fan nut. Remove shroud bolts first if needed.

6. Disconnect radiator hoses & transmission cooler lines:
- Use pliers or screwdriver to loosen clamps and slide hoses off. If stuck, gently twist hose with pliers or use a flat screwdriver to pry at the hose edge—avoid gouging metal pipe.
- If vehicle has automatic transmission cooler lines attached to radiator, have a catch pan ready. Cap lines or plug to prevent contamination; if quick‑connects are present, press release tabs.

7. Remove radiator mounting hardware:
- Remove top and lower mounting bolts, rubber isolators, and any support brackets. Keep hardware labeled/separated.
- Lift radiator straight up and out. Be careful not to damage cooling fins or AC condenser.

8. Inspect & prepare new radiator:
- Compare new radiator to old for hose locations, fittings, and sensor ports.
- Replace rubber bushings/insulators and mounting hardware if worn.
- Install O‑rings or gaskets on any fittings per service manual.
- Transfer any necessary brackets, sensor(s), and transmission line fittings.

9. Install new radiator:
- Lower radiator into position, engaging rubber mounts. Make sure condenser and fan shroud clear and align.
- Reinstall top mounts and bolts hand-tight, then torque to spec (service manual). Typical small bolts: 8–25 Nm; consult manual for exact torque.

10. Reinstall fan / shroud / accessories:
- Reinstall fan shroud assembly; for mechanical fans, reinstall fan and torque fan clutch nut to spec.
- Reconnect electrical connectors and sensors.

11. Reconnect hoses & lines:
- Slide hoses onto radiator nipples and secure with new clamps. Reconnect transmission cooler lines and tighten fittings.
- Replace thermostat & gasket at thermostat housing while accessible; torque bolts per manual.

12. Refill and bleed coolant:
- Close drain petcock. Fill radiator with pre-mixed coolant (or 50/50 mix) using a funnel.
- Start engine with heater on high and cap off (or follow vehicle bleed procedure). Let engine idle; as thermostat opens, coolant level will drop — top up as needed.
- Squeeze upper radiator hose to help expel air; repeat until no air bubbles appear and temperature stabilizes in normal range.
- Replace radiator cap once system is fully bled.

13. Test & inspect:
- Run engine to operating temperature; check for leaks at hoses, fittings, fan shroud interference, and transmission cooler lines.
- Cycle heating to ensure cabin heat works (indicates proper thermostat operation and no air pocket).
- Re-torque bolts after initial run if service manual requires.
- Road test 10–20 minutes, then recheck coolant level and for leaks. Recheck after next cold start.

How each tool is used (key items)
- Socket/ratchet & extensions: remove bolts securing fan shroud, radiator mounts, and brackets. Use correct socket size; extensions help reach recessed fasteners.
- Torque wrench: tighten critical bolts to specified torque to prevent leaks and snapped bolts.
- Pliers & hose clamp pliers: compress spring clamps or hold hose to slide off. Use hose clamp pliers for fast removal and secure installation.
- Screwdrivers: loosen worm-drive clamps and pop plastic fasteners. Use proper blade size to avoid cam-out.
- Drain pan & funnel: catch old coolant and return new coolant cleanly without spills.
- Trim tools: remove trim/fasteners without breaking tabs.
- Brass/nylon pick: remove old O‑rings without scratching mating surfaces.

Replacement parts commonly required
- Radiator (vehicle-specific)
- Radiator cap (recommended)
- Upper & lower radiator hoses (recommended if old/soft)
- Clamps (replace rusty or weak clamps)
- Thermostat & gasket (recommended when doing coolant service)
- Radiator mounting bushings/isolation mounts
- O‑rings/seals for transmission cooler lines or sensors
- Fan clutch or electric fan motor if showing play or electrical faults

Common pitfalls & how to avoid them
- Opening hot system: always allow cooling before opening radiator cap.
- Not bleeding air: air pockets cause overheating. Use the correct bleed procedure; run with heater on and squeeze hoses.
- Reusing old brittle hoses/clamps: they may leak; replace if any age or damage.
- Damaging fins or condenser: avoid prying or dropping radiator; keep plastic shrouds in place until final steps.
- Stripped or cross‑threaded fittings: start threads by hand and don’t overtighten.
- Forgetting electrical connections (fan, sensors) — causes overheating or no fan operation.
- Moving AC condenser incorrectly: do not disconnect refrigerant unless certified — work around condenser when possible or use certified A/C tech.
- Improper torque: either under- or over-torquing can cause leaks or break bolts. Use torque wrench and manual values.
- Improper coolant mix: use recommended coolant type (Toyota Long Life if specified) and proper 50/50 mix or premix.
- Environmental/legal: do not dump coolant down drains. Collect and dispose at proper recycling center.

Time estimate
- 1.5–3 hours typical for experienced tech (varies by model, tools, and whether bumper/grille removal or A/C work is needed).

Final checks
- After road test and cool-down, recheck coolant level and tighten fill cap. Inspect for slow leaks over next few days. Dispose of old coolant properly.

Follow the vehicle’s factory service manual for model-specific locations, bolt sizes, and torque specs.
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