How to Replace Radiator 01-07 Toyota Highlander L4 2.4L
Difficulty: Advanced · About 90 min · Toyota Highlander
Replace the radiator, including transferring the cooling fan, on a 2001-2007 Toyota Highlander with the L4 2.4L engine.
Tools you will need
- 12mm socket
- Funnel
- Socket extensions
- Rust penetrant
- Pick
- Side cutters
- Gloves
- Flat blade screwdriver
- Paper towels
- Wire ties
- 10mm socket
- Drain pan
- Slip-joint pliers
- Ratchet
- Needle-nose pliers
Parts and supplies
- Radiator
Steps
- Drain the radiator
Raise and support the car, spray penetrant on the splash shield's eight 10mm bolts and remove them, pry out its two push clips, pull the shield down and off, have a drain pan ready, unscrew the radiator drain by hand, twist off the cap, let it drain, then close the drain.
- Disconnect the radiator lines
Loosen the transmission cooler line clamps with pliers and disconnect the lines (securing them with a glove finger and zip tie to prevent leaks), loosen and disconnect the lower radiator hose, carefully disconnect the overflow hose, then loosen and disconnect the upper radiator hose.
- Remove the old radiator
Disconnect the fan's electrical connectors, remove the bracket's 12mm bolts and the brackets, then lift the radiator out.
- Remove the radiator fan
Remove the six 10mm bolts holding the fan assembly to the radiator, then pull it off.
- Connect the fan to the new radiator
Line the fan up on the new radiator, twist the cap on, then fasten the six 10mm bolts.
- Install the new radiator
Transfer the rubber grommets from the old radiator onto the support, lower the radiator onto them, line up the brackets and insert their 12mm bolts, then reconnect the fan's electrical connectors.
- Connect the radiator lines
Connect the upper hose and tighten its clamp, connect the overflow hose, connect the lower hose and tighten its clamp, cut off the zip ties and glove fingers from the transmission lines, connect them, wipe up any fluid, top off the transmission fluid, then tighten the cooler line clamps.
- Fill the radiator
Twist off the cap, add coolant through a funnel, turn the heat to hot without running the fan, run the engine to clear air bubbles while topping off coolant and the overflow bottle, then twist the cap back on.
- Install the splash shield
Lift it into place, insert its two push pins, then insert its eight 10mm bolts.
Check your vehicle’s repair manual for exact specifications and fit.