INSTALL INTERCOOLER ASSEMBLY
Install the intercooler assembly with the 4 bolts.
Connect the No. 1 vacuum transmitting hose to the intercooler assembly, and slide the clamp to secure it.
INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY
Install the lower radiator support sub-assembly RH with the 2 bolts.
Attach the clamp to the vacuum transmitting pipe, and then install the lower radiator support sub-assembly LH with the 2 bolts.
INSTALL NO. 2 AIR TUBE
Install the No. 2 air tube with the bolt.
Note
Before installation, remove any oil residue from the inside of the pipe and hose.
*a | 0 to 2 mm (0 to 0.0787 in.) |
Tighten the hose clamp.
Tech Tips
Position the tube end so that the distance from the intercooler pipe is 0 to 2 mm (0 to 0.0787 in.).
Connect the air temperature sensor connector.
INSTALL RADIATOR ASSEMBLY
Install the 2 radiator lower support cushions.
Insert the radiator with intercooler while holding it at an angle to install it as shown in the illustration.
Note
w/ Air Conditioning System:
Do not apply any excessive force to the cooler pipe when installing the radiator assembly.
Connect the No. 2 vacuum transmitting hose.
INSTALL CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)
Install the condenser assembly with receiver as shown in the illustration.
Tech Tips
If the condenser is replaced with a new one, add compressor oil to the new condenser.
Capacity |
---|
40 cc (1.4 fl.oz.) |
Compressor oil |
---|
ND-8 or equivalent |
INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
Install the hood lock support sub-assembly with the 4 bolts.
INSTALL HOOD LOCK ASSEMBLY
*1 | MP grease |
Apply MP grease to the sliding areas of the lock.
for LHD:
Connect the hood lock control cable.
Install the hood lock with the 3 bolts.
for RHD:
Connect the hood lock control cable.
Connect the connector.
Install the hood lock with the 3 bolts.
INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY
Install the 2 upper radiator supports with the 4 bolts.
Install the 2 radiator support cushions.
INSTALL UPPER RADIATOR SUPPORT
Install the 2 upper radiator supports with the 2 bolts.
CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.
Compressor oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring to the air conditioning tube and accessory assembly.
Connect the air conditioning tube and accessory assembly to the cooler condenser assembly with the bolt.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
Remove the attached vinyl tape from the pipe and connecting part of the cooler condenser assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
Compressor oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring to the discharge hose sub-assembly.
Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.
INSTALL NO. 3 AIR HOSE
Note
Before installation, remove any oil residue from the inside of the throttle body and tube.
*1 | Embossed Mark |
*2 | Paint Mark |
*a | Rear Side |
*b | RH Side |
Align the paint mark of the No. 3 air hose with the embossed mark of the throttle body.
Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.
Tighten the clamp of the No. 3 air hose on the diesel throttle body side.
Tech Tips
Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).
Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.
Tech Tips
Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).
INSTALL INTERCOOLER AIR HOSE
Note
Check that the retainer is closed when the connector is inserted.
If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.
If replacing the hose, apply fresh oil to the O-ring.
Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.
Do not use a quick connector that has been dropped.
*1 | Retainer |
Install the intercooler air hose to intercooler and No. 1 air tube and push in the retainer.
Tighten the hose clamp.
CONNECT NO. 2 RADIATOR HOSE
*1 | Matchmark |
*a | Top |
*b | LH Side |
Connect the No. 2 radiator hose and slide the clamp to secure it.
Tech Tips
Position the clamp as illustrated.
INSTALL NO. 1 RADIATOR HOSE
*1 | Matchmark |
*a | View A |
*b | View B |
*c | Top |
*d | LH Side |
Connect the No. 1 radiator hose and slide the 2 clamps to secure it.
Tech Tips
Position clamps A and B as Illustrated.
INSTALL INJECTOR DRIVER
Install the injector driver bracket with the 4 screws.
Install the injector driver with the 3 bolts.
Attach the clamp and connect the 4 connectors.
CONNECT NO. 1 WATER HOSE CLAMP BRACKET
Connect the No. 1 water hose clamp bracket to the radiator support with the 2 bolts.
Connect the No. 2 by-pass water hose and slide the 2 clamps to secure it.
Connect the No. 1 radiator hose to the No. 1 water hose clamp bracket and slide the clamp to secure it.
INSTALL NO. 3 WATER BY-PASS HOSE
Connect the 3 connectors and attach the clamp.
Install the No. 3 water by-pass hose and slide the clamp.
Connect the No. 3 water by-pass hose to the radiator assembly, and slide the clamp to secure it.
INSTALL NO. 2 RADIATOR SIDE AIR SEAL
Install the No. 2 radiator side air seal.
INSTALL NO. 1 RADIATOR SIDE AIR SEAL
Install the No. 1 radiator side air seal.
INSTALL LOW PITCHED HORN ASSEMBLY
Connect the horn connector to install the low pitched horn assembly.
Install the bolt.
CONNECT AMBIENT TEMPERATURE SENSOR
Attach the clamp to install the sensor.
Connect the connector.
INSTALL BATTERY CARRIER
Install the battery carrier with the 4 bolts.
Attach the 2 clamps to connect the wire harness.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
Attach the hook of the battery clamp sub-assembly to the battery carrier.
Partially tighten the nut and temporarily install the bolt.
Adjust the battery clamp sub-assembly position.
Tighten the nut and bolt.
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.
Standard Capacity | ||||||
---|---|---|---|---|---|---|
|
Note
Never use water as a substitute for engine coolant.
Tech Tips
TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).
*1 | Air Release Plug |
B Line |
Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.
Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.
Install the cap and air release plug, and warm up the engine sufficiently.
Bleed air from the cooling system.
Note
Before starting the engine, turn the A/C switch off.
Adjust the air conditioning temperature setting to MAX (HOT).
Adjust the air conditioning blower setting to Lo.
Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
CAUTION:
When squeezing the radiator hoses:Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fan.
Tech Tips
The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand and sensing vibrations when the engine coolant starts to flow inside the hose.
After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern at least 8 times).
Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
CAUTION:
When squeezing the radiator hoses:Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fan.
After the engine has cooled down, check that the coolant level is between FULL and LOW.
If the coolant level is low, add coolant until the coolant level leaks the reservoir tank FULL line.
CHARGE REFRIGERANT (w/ Air Conditioning System)
Perform vacuum purging using a vacuum pump.
Charge refrigerant HFC-134a (R134a).
Standard |
---|
440 +/-30 g (15.5 +/-1.1 oz) |
Note
Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
Approximately 100 g (3.53 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
WARM UP ENGINE (w/ Air Conditioning System)
Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
Note
Be sure to warm up the compressor by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.
INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation observing the following instructions:
Stop the engine.
Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
Repeat the test 2 or 3 times.
Make sure that some refrigerant remains in the refrigeration system.
Tech Tips
When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).
*1 | Check for Leakage |
*2 | Halogen Leak Detector |
Using a halogen leak detector, check the refrigerant line for leakage.
If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.
INSPECT FOR COOLANT LEAK
Remove the radiator reservoir cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
Fill the radiator with coolant, and then attach a radiator cap tester.
Warm up the engine.
Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
Reinstall the radiator reservoir cap.
INSTALL NO. 1 ENGINE COVER
Attach the 4 clips to install the No. 1 engine cover.
INSTALL FRONT LOWER BUMPER ABSORBER
Insert the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.
Install the 4 bolts.
Install the 2 clips.
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 10 clips and 6 bolts.
INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY