Toyota Radiator Hose Replacement Manual

Please refer to the following sources for additional information:

• Your vehicle’s Owner’s Manual

• Your vehicle’s Repair Manual

Moving parts like the fan blade and drive belts, as well as extreme
heat in the engine compartment or from the exhaust system can
result in serious injury.

• Approach with caution and care.

• Never take shortcuts when replacing parts.

• Improper servicing may damage your Toyota and lead to
personal injury.

• Unless you have proper knowledge, equipment and tools, you
should have your Toyota Dealer Service Department perform
the repair s and maintenance.

Proper installation of Genuine Toyota replacement parts is essential
for the safe and reliable operation of your vehicle.

Following these instructions will:

• Help to assure your personal safety

• Assist you in the proper replacement of specific parts

There are many variations in the step-by-step procedures used in
installing various parts, and varying skill levels of individuals doing
the parts replacement. These instructions cannot anticipate all
circumstances or provide advice and caution on each. If you are
in doubt concerning your ability to replace the part or have any
questions, consult your local Toyota Dealer Service Department
and have the work performed by an experienced technician.

For further assistance, contact your Toyota dealer.

REFERENCES

CAUTION

IMPORTANT SAFETY NOTICE

Visit our Web site at www.toyota.com

M/N 00405-HOWTO-RHOSE

The “Check Engine” light
comes on:

Take the vehicle to your Toyota
Dealer Service Department for
diagnosis and repair.

CONDITION ACTION

Engine runs hot or overheats: Check the coolant level in the

radiator when the engine is cold.

Check the radiator hoses and
drain plugs for leaks.

Remove the radiator cap when
the engine is cold; run the
engine for 5-10 minutes with
the radiator cap removed to
release air bubbles from the
cooling system (this procedure
may need to be repeated).

With the engine off and the
coolant still warm, touch the
upper and lower radiator
hoses. They should both be
warm. If one is cold, the
thermostat could be stuck in
the closed position. Refer to
the “How to Replace a
Thermostat” brochure.

If the problem persists, visit
your Toyota Dealer Service
Department for diagnosis and
repair. DO NOT DRIVE THE
VEHICLE if the engine
overheats.

TROUBLESHOOTING

RECHECK THE COOLANT LEVEL – Shut the engine off, allow
it to cool and check the coolant level. Fill the radiator as
required. Check the coolant level in the coolant recovery
reservoir and refill as required. Refer to the Owner’s Manual
for exact fill level specifications.

INSTRUCTIONS

(continued)

16

RECORD THE DATE AND MILEAGE OF THE HOSE AND
RADIATOR FLUID CHANGE (if performed) IN YOUR SERVICE
MAINTENANCE LOG. CHECK THE SCHEDULED MAINTENANCE
GUIDE TO ASSURE ALL MAINTENANCE IS PERFORMED AT
THE APPROPRIATE TIME FOR THE MILEAGE.

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DIFFICULTY LEVEL

• Genuine Toyota Radiator Hose

• Hose clamps – 2 for each hose

• Genuine Toyota Coolant as required

• Phillips (+ shaped) screwdriver (medium)

• Flat-tip (– shaped) screwdriver (medium)

• Pliers

• Radiator drain plug (hex-head) wrench (if needed)

• Drain pan (large enough to hold 2 to 3 gallons of coolant
and still fit under the vehicle)

• Metal file

• Disposable gloves

• Eye protection

• Rags or paper towels

CAUTION: DO NOT install a new hose over a damaged fitting.

Smooth out any rough edges with a metal file. If more severe
damage is noted, see your Toyota dealer.

mWARNING: Keep your hands and
tools away from the fan. Do not lean
on the fan housing. If the battery is
not disconnected, the fan could
automatically come on at any time.

30-45
MINUTES

FROM ONE TO FOUR–FOUR BEING THE MOST DIFFICULT

HARD TO SERVICE MODELS

TOOLS AND SUPPLIES

INSTRUCTIONS

(continued)

INSTRUCTIONS

(continued)

DRAIN COOLANT INTO CONTAINER –
Slowly remove the radiator cap to
relieve pressure in the cooling
system. Position the clean container under the radiator drain
plug located in the lower section of the radiator. If the drain
plug is the flat type, using pliers, turn the drain plug
counterclockwise and allow the coolant to drain. If the drain
plug is the hex-head type, use a hex-head wrench, turn
counterclockwise and allow the coolant to drain. When enough
coolant has been drained, turn the drain plug clockwise to
tighten.

DO NOT OVER-TIGHTEN.

NOTE: If only the upper radiator hose is being replaced, it is

not necessary to drain out all of the coolant. Drain about one
gallon to ensure the coolant level is below the hose.

NOTE: If you are replacing the lower radiator hose and the
coolant is over 2 years old, it is also recommended to drain the
coolant from the engine block at the same time as the radiator
(see step 13). Refer to your vehicle’s Owner’s Manual for the
location of the engine drain plug.

3

LOOSEN THE HOSE CLAMP – Using
a screwdriver or hose clamp pliers,
loosen the hose clamp on one end
of the hose and push it back a
couple of inches. The flat-tip
screwdriver may be used to help
move the clamp if it is difficult to
move by hand.

4

DISCONNECT THE HOSE FROM
THE FITTING – Twist the hose back
and forth to loosen it. Pull firmly
on the hose – it will be difficult to
get started but should come off
easily after being loosened. Be
careful not to damage the flange.

5

DISCONNECT THE OTHER END
OF THE HOSE AS STATED IN
STEPS 4 & 5.

6

INSPECT THE HOSE FITTING –
Carefully feel around the outside
lip of the flange with your finger.
Check for rough edges, burrs and
deformation.

7

8

PUSH THE HOSE ONTO THE RADIATOR AND ENGINE FITTING –
Apply a small amount of water or coolant inside of the new
hose and twist and push the hose over the fitting as far as it
will go.

PUT NEW HOSE CLAMPS OVER EACH END OF THE NEW HOSE –
Loosely install the hose clamps 3 or 4 inches from the hose ends.

9

INSPECT THE HOSE INSTALLATION – Check that the hose
routing is correct, not twisted, and clear of other engine
components.

10

INSTALL THE HOSE CLAMPS – Slide the hose clamps over the
lip of the fitting approximately one inch from the end of the hose.

11

TIGHTEN THE HOSE CLAMPS (if screw type) UNTIL THE
SURFACE OF THE CLAMP IS FLUSH WITH THE RUBBER HOSE –
If the clamps are spring type, this operation is not required.

CAUTION: DO NOT OVER-TIGHTEN the clamps.

12

FILL THE RADIATOR WITH COOLANT – Slowly add coolant to
insure proper filling. Rapid filling will not allow air to escape
from the cooling system. If the old coolant is more than 2 years
old, flush the cooling system with water and replace coolant
with 50 to 70% anti-freeze and 50 to 30% water. Bleed air out
of the system (see Repair Manual for your vehicle’s bleeding
requirements.)

Super Long Life Coolant is pre-mixed, there is

no need to add water.

CAUTION: Do not bleed system while
engine is hot – severe burns may result.

mWARNING: Do not pour coolant onto
the ground or into a storm drain or sewer
– it is environmentally unsafe and illegal.
Put the coolant into plastic containers and take them to a service
station, recycling center or your Toyota Dealer Service Department
for recycling. USED COOLANT MAY CONTAIN HEAVY METALS
AND IS TOXIC. Be sure to clean up any coolant that has spilled
on your hands, clothes, the vehicle, or the ground. Animals are
attracted to spilled coolant and can be fatal if ingested.

13

RE-CONNECT NEGATIVE BATTERY CABLE.

14

CHECK THE HOSE CONNECTIONS FOR LEAKAGE – Start the
engine and run the engine until it reaches normal operating
temperature, then check for fluid leaks at the hose connections.

15

ESTIMATED TIME INVOLVED

Accessibility problems may exist on some Toyota models such
as the MR2, MR2 Spyder, Toyota Van (’84-’89), Previa and turbo
or supercharged models. Unless you have proper knowledge,
equipment and tools, have your Toyota Dealer Service Department
perform the repair.

INSTRUCTIONS

ALWAYS REMOVE THE KEYS FROM THE IGNITION WHEN
WORKING ON THE VEHICLE. SEE

CAUTION ON BACK PANEL.

NOTE: Radiator hose replacement should be performed on a

level surface when the engine is cool. Otherwise the system
will be under pressure and the coolant may be hot enough to
burn. Radiator caps should never be removed when the engine
is hot. Set the parking brake and wear disposable gloves and
eye protection.

1

DISCONNECT THE NEGATIVE
BATTERY TERMINAL CABLE.

NOTE: On some vehicles, the
alarm will sound when the
battery is reconnected. Also,
clocks and radio station presets
will have to be reset after the
battery is reconnected (refer to
your vehicle’s Owner’s Manual
for instructions).

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