KZJ95 4Runner radiator retrofit

[OM617YOTA]

Alrighty, got my radiator retrofitted. Most of this is nothing new, but I didn't see it posted all in one place anywhere else on the forum, so here goes.

Radiator is Denso PN 42406, meant for a 2000 4Runner 2.7l. Think the 3.4l used the same radiator. Bolts in exactly the same, but the top and bottom hoses are on opposite sides, so hoses have to be modified accordingly.

Upper radiator hose is a mix of the factory upper radiator hose 16571-67070, Dayco C71280, a straight piece of 1.5" radiator hose. I cut them apart, used bends where needed, used couplers to re-clock orientation, and then connected them all up with Amazon aluminum radiator hose couplers and a pile of hose clamps.

Lower radiator hose is the factory hose PN 16572-67070, split in the center and extended with a straight piece of 1.5" radiator hose, more couplers, and hose clamps.

I added a coolant temperature sensor probe for an Auber Instruments display to one of the couplers on the lower hose, but I goofed. I wanted it on the outlet from the engine and didn't realize that the thermostat controlled coolant going in, not coming out. I'll have to swap that at some point.

While I had the system open, I replaced the rubber hoses leading to the turbo(didn't get a pic), and the heater hoses. These U-bends are Dayco B70553, Carquest 20625, or Napa 7388. I had to trim one slightly. Mixer valve has been added to the list of things to replace.

Replaced the heater hoses on the other side with standard 3/4" heater hose. Bypassed the lines leading to the rear heater. Completely unneeded for me, just an additional failure point. I added enough of those already.

 

[OM617YOTA]

Engine warmed up and thermostat opening, thermal pics showing coolant starting to move through the top hose and heater hose. Looks like I need to recalibrate the alignment on my Flir.

 

[OM617YOTA]

Alrighty, the ONE piece in the cooling system that I didn't replace was the heater control valve. Would you all care to guess what failed and started leaking?

Factory heater control valve PN for the KZJ95 is 87240-35030.

I didn't want to order from the usual folks overseas and wait for the part to arrive, so decided to see if the heater control valve from the same 2000 4Runner as the radiator would work. Napa PN BK6601374.

Sure enough, it does. You have to pull the actuator lever and swap over the lever from your factory heater control valve, but otherwise it's the same and fits perfectly.

Differences between the levers as-installed.

Pulled screws, yup looks the same other than the lever.

Swapped lever, fits perfectly.

New valve mounted in housing with lever and actuator cable holder.

Put everything back together, haven't test driven yet but idled until up to full operating temperature. First time not smelling coolant since I've owned the vehicle.

 

[OM617YOTA]

Alrighty, bit of an update.

4Runner radiator is functioning perfectly.

My adapter hoses, not so much. They're seeping coolant out of the cords on the cut ends of the hoses, and I smell coolant every time I drive it. Have only had to add a few ounces of coolant once since installed, but far from ideal and I have grave concerns about adapter hose integrity. Coolant seeping out of cords = hoses are compromised despite being brand new; I fear a catastrophic failure as we move into summer.

Pondering either this radiator and factory hoses:

64637A - Radiator, engine cooling

64637A - Radiator, engine cooling manufactured by NISSENS applicable for the TOYOTA. This radiator is fully compatible with original part numbers 1640067141, 16400-67121, and 16400-67140. Order NISSENS radiator online and find many other parts and accessories that fit your car, bike or truck.

spareto.com

Or redoing my conversion hoses.

Anyone have any tips or tricks?

 

[OM617YOTA]

Radiator just arrived from Spareto. Looks decent, not pleased about how poorly the fins were protected. They're fine, but not pristine as I would have hoped they'd be.

OEM hoses inbound.

 

[OM617YOTA]

Alrighty, update time. One of the radiator hoses I cut apart to build conversion hoses for a 4Runner radiator was compromised, it was about to burst despite being new. Probably could have replaced just that chunk and been fine. Happier being back to a more stock configuration.

New Nissens radiator and OEM hoses installed. System bled much easier than last time with the conversion radiator, happy about that. Drives + maintains temperature exactly as it should. Direct replacement + lower cost than a locally sourced 4Runner radiator and conversion hoses; as long as this option is available don't bother retrofitting a 4Runner radiator, it's just not worth the trouble.

Not overly pleased with the condition of the Nissens radiator when it arrived. It'll be fine and I'm using it without qualms, but if I got something similar from Napa or a local store, I'm not sure I'd accept it.

If anyone needs a 2000 4Runner radiator with only a few months use on it, I'll sell you one for half the price of new............

 

[little_joe]

Really do appreciate you keeping this updated - and congrats on getting this sorted and setting your mind at ease! The details and part numbers you provided are a huge help to me, and likely to many others.

 

[OM617YOTA]

Glad to help! Just posting what I myself had hoped to find before starting this journey.