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Autopapyrus · Toyota Tercel 1.5 5E-FE (1991)
https://autopapyrus.com/guides/toyota/tercel/radiator-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Toyota Tercel 1.5 5E-FE (1991): Radiator Replacement

The radiator on the Tercel L50 is aluminum-and-plastic (or copper, depending on the supply), mounted at the front and secured to the body by upper brackets. On automatic transmission models, a fluid cooler is built into the lower tank, so the transmission lines must be disconnected carefully. The job is not difficult, but it requires care when draining and bleeding the system.

Difficulty: Medium Time: 1.5-3 hours Steps: 12 Tools: socket and wrench set (8, 10, 12, 14 mm), screwdrivers, hose clamp pliers, coolant drain pan (at least 6 L (6.3 qt)), funnel, gloves, jack stands or a pit

Part

  • 🔩 Complete radiator. Per catalogs for the 1991-1994 Tercel, Toyota part numbers 16400-11500 (manual transmission and 3-speed automatic) and 16400-11530 (4-speed automatic) are listed. Check against your transmission and the appearance of your old radiator. Aftermarket alternatives: Nissens, Koyorad, Fenix, Denso. Also needed: coolant (antifreeze), 5-6 L (5.3-6.3 qt), new hose clamps, and new hoses if the old ones are worn
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 1 more. See manuals →

Step by step

12 steps
  1. Wait until the engine has cooled completely. Disconnect the negative battery terminal. Park the car on level ground and, if needed, raise the front and support it on jack stands.
  2. Remove the engine splash shield if one is installed. Place the drain pan under the radiator.
  3. Remove the radiator cap (only on a cold engine), open the drain cock at the bottom of the radiator, and drain the coolant. If the drain cock is rusted or won't open, don't force it. Remove the lower hose instead. For a more complete drain, you can also open the drain plug on the cylinder block (optional).
  4. Disconnect the upper and lower radiator hoses, as well as the coolant reservoir hose. Loosen the clamps with pliers and twist the hoses on the necks to remove them without damage.
  5. On automatic transmission versions, disconnect the two transmission fluid cooler lines from the radiator. Place a pan underneath, since a small amount of transmission fluid will leak out. Plug the line ends to keep dirt out, and check the automatic transmission fluid level after installation.
  6. Disconnect the temperature sensor or fan connector if it is on the radiator. Remove the fan shroud and the electric fan by removing the fasteners. The fan can be removed together with the shroud.
  7. Remove the upper brackets that secure the radiator to the body. Carefully lift the radiator up, taking care not to damage the A/C condenser fins (on cars with air conditioning) or the fan.
  8. Transfer the lower rubber mounts and cushions, plastic parts, and sensors (if there were any) to the new radiator. Check the condition of the rubber mounts and replace them if they are cracked.
  9. Install the new radiator in reverse order: first the lower mounts, then the upper brackets. Connect the hoses, transmission lines, and connectors, and install the fan shroud. Tighten the fasteners without excessive force. The manufacturer does not strictly specify a torque for the radiator, so tightening until snug, without deforming the plastic, is enough.
  10. Close the drain cock, then fill with coolant up to the radiator filler neck and the coolant reservoir up to the MAX level. Turn the heater on at maximum heat.
  11. Start the engine with the radiator cap off. Let it warm up until the thermostat opens and the fan runs. Add coolant as the air escapes, and make sure the bubbles are clearing. Install the cap.
  12. Check the connections for leaks with the engine warm. Let it cool, recheck the level, and top up if necessary. On automatic transmission models, check the transmission fluid level. After a few days of driving, check the coolant level and look for leaks again.

Common mistakes and warnings

  • Never open the radiator cap on a hot engine: you could be burned by steam and boiling coolant. Antifreeze is toxic to animals and people, so dispose of it properly. An air pocket in the system causes overheating and can warp the cylinder head, so be sure to bleed the air out and watch the temperature after the replacement.