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It's hardly a difficult thing to do, but I don't think anyone's written step by step instructions, and it's a common task, so here it is. The prettier/permanent version is here.
The main radiator in the Hilux Surf is used to cool both the engine coolant and, for those with automatic transmissions, the ATF.
In the KZN130 (3 litre) 2nd gen, an air conditioning radiator may be fitted in front of the top half of the main radiator. In the LN130 (2.4 litre), it may be fitted across the bottom of the engine bay, flat along the top of the bash plate.
Removal of the radiator can be completed in about one hour.
Tools/Equipment needed
* Flat blade screw driver
* 10 & 12mm sockets
* Large pliers/vice grips
* Cable ties
Remove the bash plate (already done in these pictures), by removing the two M12 bolts at the front and 2 at the back.
Lower Radiator Connections
Drain the radiator fully by removing the drain plug and the radiator cap (A).
Use large pliers to move the clip back along both ATF hoses, away from the radiator (the further one is partially hidden by coolant pipe C in the picture). Create a fold in the hoses, as shown, and cable tie over to prevent ATF leaking. Note that some will still leak from radiator - have a tray ready to catch it. Carefully twist loose and remove ATF hoses (B).
Use large pliers again to move clip on coolant exit hose C away from radiator. Carefully pry hose loose and remove. Note that more coolant will drain from this hose - have a tray ready to catch it!
Upper Radiator Connections
Remove the hot coolant return pipe A from the top of the radiator in the same manner.
Either remove the coolant overflow pipe B, or simply remove the lid from the expansion tank and leave attached to the radiator.
Use 10mm socket to remove the bolts A holding the vacuum pipe mounted to top of radiator.
Radiator Removal
Use 10mm socket to remove the 4 bolts A holding the fan shroud from the back of the radiator. Picture shows the right side of the radiator, the other two bolts are on the left. The lower bolts may be more easily accessed from below.
Pull the shroud away from the radiator. It's not necessary to remove it.
Use 12mm socket to remove the 4 bolts A holding the radiator in place. Picture shows the right side of the radiator, the other two bolts are on the left. As before, the lower bolts may be more easily accessed from below.
The radiator should now be left sitting on two small locating pins. Lift it up, tilting it forward as you go, and it should lift free. A second pair of hands to keep pipes, the fan shroud etc out of the way is certainly useful at this point.
The radiator can be laid safely on its back, with all exits pointing up.
The main radiator in the Hilux Surf is used to cool both the engine coolant and, for those with automatic transmissions, the ATF.
In the KZN130 (3 litre) 2nd gen, an air conditioning radiator may be fitted in front of the top half of the main radiator. In the LN130 (2.4 litre), it may be fitted across the bottom of the engine bay, flat along the top of the bash plate.
Removal of the radiator can be completed in about one hour.
Tools/Equipment needed
* Flat blade screw driver
* 10 & 12mm sockets
* Large pliers/vice grips
* Cable ties
Remove the bash plate (already done in these pictures), by removing the two M12 bolts at the front and 2 at the back.
Lower Radiator Connections
Drain the radiator fully by removing the drain plug and the radiator cap (A).
Use large pliers to move the clip back along both ATF hoses, away from the radiator (the further one is partially hidden by coolant pipe C in the picture). Create a fold in the hoses, as shown, and cable tie over to prevent ATF leaking. Note that some will still leak from radiator - have a tray ready to catch it. Carefully twist loose and remove ATF hoses (B).
Use large pliers again to move clip on coolant exit hose C away from radiator. Carefully pry hose loose and remove. Note that more coolant will drain from this hose - have a tray ready to catch it!
Upper Radiator Connections
Remove the hot coolant return pipe A from the top of the radiator in the same manner.
Either remove the coolant overflow pipe B, or simply remove the lid from the expansion tank and leave attached to the radiator.
Use 10mm socket to remove the bolts A holding the vacuum pipe mounted to top of radiator.
Radiator Removal
Use 10mm socket to remove the 4 bolts A holding the fan shroud from the back of the radiator. Picture shows the right side of the radiator, the other two bolts are on the left. The lower bolts may be more easily accessed from below.
Pull the shroud away from the radiator. It's not necessary to remove it.
Use 12mm socket to remove the 4 bolts A holding the radiator in place. Picture shows the right side of the radiator, the other two bolts are on the left. As before, the lower bolts may be more easily accessed from below.
The radiator should now be left sitting on two small locating pins. Lift it up, tilting it forward as you go, and it should lift free. A second pair of hands to keep pipes, the fan shroud etc out of the way is certainly useful at this point.
The radiator can be laid safely on its back, with all exits pointing up.
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