THERMOSTAT (w/o EGR Cooler) INSTALLATION


  1. INSTALL THERMOSTAT


    1. A01DVHYE01

      Install a new gasket to the thermostat.

      Tech Tips

      When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

    2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set within 30°of either side of the prescribed position.

  2. INSTALL WATER INLET


    1. A01DZUQE01

      Install the inlet with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  3. INSTALL NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


    1. A01DX6PE01

      Connect the clamp to the inlet with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  4. INSTALL COMPRESSOR INLET ELBOW

    A01DZ8S

    1. Install a new gasket and inlet elbow with the 2 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the ventilation pipe to the cylinder head cover.

    3. Move the clamp to the joint pipe of the hose.

    4. Install the ventilation pipe with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    5. Connect the 2 connectors to the turbocharger.

    6. Install the harness clamp's clip to the inlet elbow.

  5. CONNECT RADIATOR HOSE INLET


    1. Connect the hose to the water inlet.

  6. INSTALL CHARGE AIR COOLER ASSEMBLY


    1. Install the charge air cooler Click here.

  7. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Install the cover with the 3 bolts and 2 nuts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  8. INSTALL AIR CLEANER ASSEMBLY

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    1. Connect the air cleaner hose.

    2. Install the cleaner with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    3. Tighten the hose clamp of the compressor inlet elbow.

    4. Connect the MAF meter connector and install the clamp.

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  10. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01DYVNE01

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 9.8 liters (10.4 US qts, 8.6 Imp. qts)

      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 consists of a combination of low phosphates and organic acids).


      • Please contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 2,500 to 3,000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.


        • Be careful as the radiator hoses are hot.


        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

      If the coolant level is below the F line, add TOYOTA SLLC to the F line.

  11. CHECK FOR ENGINE COOLANT LEAKS


    1. Check for the engine coolant leaks Click here.

  12. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  13. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.