Toyota Prius: Radiator
On-vehicle Inspection
ON-VEHICLE INSPECTION
CAUTION / NOTICE / HINT
CAUTION:
Do not remove the reserve tank cap, radiator cap sub-assembly or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
PROCEDURE
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
CAUTION:
Do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
(a) Measure the valve opening pressure.
| *a | Rubber Packing (1) |
| *b | Rubber Packing (2) |
| *c | Rubber Packing (3) |
| *d | Valve Seat |
(1) If there are water stains or foreign matter on the rubber packings (1), (2) or (3), clean the part(s) with water and finger scouring.
(2) Check that the rubber packings (1), (2) and (3) are not deformed, cracked or swollen.
(3) Check that the rubber packing (3) and valve seat are not stuck together.
(4) Apply engine coolant to the rubber packings (2) and (3) before using a radiator cap tester.
(5) Install the radiator cap tester to the radiator cap sub-assembly.
| (6) When using the radiator cap tester, tilt it upward 30° or more. |
|
(7) Pump the radiator cap tester several times, and check the maximum pressure.
Pumping Speed:
1 pump per second
| Item | Specified Condition | Result |
|---|---|---|
| Standard pressure (for brand-new radiator cap sub-assembly) | 74 to 103 kPa 0.8 to 1.1 kgf/cm2 10.7 to 14.9 psi | kPa kgf/cm2 psi |
| Minimum pressure (for used radiator cap sub-assembly) | 59 kPa 0.6 kgf/cm2 8.6 psi | kPa kgf/cm2 psi |
HINT:
Even if the radiator cap sub-assembly cannot maintain the maximum pressure, it is not a defect.
If the maximum pressure is less than the minimum pressure, replace the radiator cap sub-assembly.
(8) Remove the radiator cap tester from the radiator cap sub-assembly.
2. CHECK RADIATOR ASSEMBLY FOR CLOGGING
CAUTION:
To prevent burns, do not touch the engine or other high temperature components while the engine is hot.
Pre-procedure1
(a) Remove the fan with motor assembly.
HINT:
Click here
Procedure1
(b) Shine an electric light at the radiator assembly and cooler condenser assembly from the front of the cooler condenser assembly and check the radiator assembly for clogging using a mirror.
| *a | OK | *b | NG |
| *c | Electric Light | *d | Mirror |
OK:
The radiator assembly is not clogged.
If the radiator assembly is clogged, clean it.
Post-procedure1
(c) Install the fan with motor assembly.
HINT:
Click here
3. CLEAN RADIATOR ASSEMBLY
CAUTION:
To prevent burns, do not touch the engine or other high temperature components while the engine is hot.
Pre-procedure1
(a) Remove the fan with motor assembly.
HINT:
Click here
(b) Cover the opening of each air duct with a piece of cloth.
Procedure1
(c) Clean the cooler condenser assembly.
(1) Check that the washer nozzle is not clogged.
| (2) Insert the washer nozzle into the space in front of the cooler condenser assembly and spray it. NOTICE:
|
|
(3) Leave the cooler condenser assembly as is for 10 minutes to let the water penetrate the dirt.
(4) Clean the cooler condenser assembly again.
NOTICE:
- Clean the fins of the cooler condenser assembly by spraying the entire area for 150 seconds. Repeat this process 4 times.
- Set the air pressure to 0.4 MPa (4.1 kgf/cm2, 58 psi).
- Check that water sprays in mist form from the washer nozzle.
- Keep the washer nozzle parallel to the cooler condenser assembly.
- Do not allow the washer nozzle to contact the fins of the cooler condenser assembly.
- Keep the washer nozzle moving while spraying water.
- Do not spray the cooler compressor assembly or generator assembly excessively.
(5) Using an air blow gun, dry the cooler condenser assembly for 3 minutes.
Procedure2
(d) Clean the radiator assembly.
| (1) Insert the washer nozzle into the space in rear of the radiator assembly and spray it. NOTICE:
|
|
(2) Leave the radiator assembly as is for 10 minutes to let the water penetrate the dirt.
(3) Clean the radiator assembly again.
NOTICE:
- Clean the fins of the radiator assembly by spraying the entire area for 150 seconds. Repeat this process 4 times.
- Set the air pressure to 0.4 MPa (4.1 kgf/cm2, 58 psi).
- Check that water sprays in mist form from the washer nozzle.
- Keep the washer nozzle parallel to the radiator assembly.
- Do not allow the washer nozzle to contact the fins of the radiator assembly.
- Keep the washer nozzle moving while spraying water.
(4) Using an air blow gun, dry the radiator assembly for 3 minutes.
Procedure3
(e) Check the fins of the radiator assembly for clogs again.
If the radiator assembly is clogged, clean the cooler condenser assembly and radiator assembly again.
Post-procedure1
(f) Remove the piece of cloth from the opening of each air duct.
(g) Install the fan with motor assembly.
HINT:
Click here
Removal
REMOVAL
CAUTION / NOTICE / HINT
The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during radiator assembly removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced| Replaced Part or Performed Procedure | Necessary Procedures | Effect/Inoperative Function When Necessary Procedures are not Performed | Link |
|---|---|---|---|
| *1: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation. | |||
| Front bumper assembly*1 | Front television camera view adjustment | Panoramic View Monitor System |
|
| Advanced Park |
| ||
| Replacement or removal and installation of 2 or more parts:
| Television camera view adjustment | Panoramic View Monitor System |
|
CAUTION / NOTICE / HINT
COMPONENTS (REMOVAL)
| Procedure | Part Name Code |
|
|
| |
|---|---|---|---|---|---|
| 1 | FAN WITH MOTOR ASSEMBLY | - | - | - | - |
| 2 | RADIATOR ASSEMBLY | 16400 |
| - | - |
| 3 | RADIATOR SUPPORT CUSHION | 16523A | - | - | - |
| 4 | RADIATOR SUPPORT GROMMET | 16533C | - | - | - |
| 5 | RADIATOR DRAIN COCK PLUG | 16400B | - | - | - |
| *1 | O-RING | - | - |
PROCEDURE
1. REMOVE FAN WITH MOTOR ASSEMBLY
Click here
2. REMOVE RADIATOR ASSEMBLY
(1) Disengage the 2 claws.
(2) Disengage the 2 guides to separate the cooler condenser assembly from the radiator assembly.
NOTICE:
Make sure not to damage the cooler condenser assembly when separating the cooler condenser assembly.
(3) Remove the radiator assembly from the Toyota Prius vehicle body.
NOTICE:
Do not apply excessive force to the cooler condenser assembly or pipe when removing the radiator assembly.
3. REMOVE RADIATOR SUPPORT CUSHION
4. REMOVE RADIATOR SUPPORT GROMMET
5. REMOVE RADIATOR DRAIN COCK PLUG
Installation
INSTALLATION
CAUTION / NOTICE / HINT
COMPONENTS (INSTALLATION)
| Procedure | Part Name Code |
|
|
| |
|---|---|---|---|---|---|
| 1 | RADIATOR DRAIN COCK PLUG | 16400B |
| - | - |
| 2 | RADIATOR SUPPORT GROMMET | 16533C | - | - | - |
| 3 | RADIATOR SUPPORT CUSHION | 16523A | - | - | - |
| 4 | RADIATOR ASSEMBLY | 16400 |
| - | - |
| 5 | FAN WITH MOTOR ASSEMBLY | - | - | - | - |
| *1 | O-RING | - | - |
PROCEDURE
1. INSTALL RADIATOR DRAIN COCK PLUG
(1) Install the O-ring to each radiator drain cock plug.
NOTICE:
Replace the O-ring if it is damaged.
(2) Install the 2 radiator drain cock plugs.
2. INSTALL RADIATOR SUPPORT GROMMET
3. INSTALL RADIATOR SUPPORT CUSHION
4. INSTALL RADIATOR ASSEMBLY
(1) Install the radiator assembly to the Toyota Prius vehicle body.
NOTICE:
Do not apply excessive force to the cooler condenser assembly or pipe when installing the radiator assembly.
(2) Engage the 2 guides.
(3) Engage the 2 claws to install the cooler condenser assembly to the radiator assembly.
NOTICE:
Do not damage the cooler condenser assembly when installing the cooler condenser assembly.
5. INSTALL FAN WITH MOTOR ASSEMBLY
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Toyota Prius (XW60) 2023-2025 Service Manual
Radiator
Actual pages
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