THERMOSTAT (w/o DPF) INSTALLATION


  1. INSTALL THERMOSTAT

    A01KHH6E04
    Text in Illustration
    *1 Gasket
    *2 Jiggle Valve
    *a CORRECT
    *b INCORRECT
    *c Upward

    1. 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 vertical in either direction.

  2. INSTALL WATER INLET

    A01KFDO

    1. Install the water inlet with the 3 bolts.

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

      Note

      Tighten the 2 upper bolts first.

  3. CONNECT OUTLET RADIATOR HOSE

    A01KHB2E02
    Text in Illustration
    *a Upper
    *b Right

    1. Connect the outlet radiator hose with the hose clamp as shown in the illustration.

  4. INSTALL OIL LEVEL GAGE GUIDE (for LHD)


    1. Apply engine oil to a new O-ring.

    2. Install the O-ring to the oil level gage guide.

    3. Install the oil level gage guide with the bolt.

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

    4. Install the oil level gage.

    5. A01KEBI

      Install the wire harness clamp bracket with the 2 bolts and connect the connector.

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

  5. INSTALL NO. 1 AIR HOSE


    1. Connect the No. 1 air hose and tighten the hose clamp.

  6. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for Double Cab)


    1. Connect the wire harness and install the engine side cover sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 in.*lbf }

  7. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH (for Double Cab)


    1. A01KGS6

      Install the fender side apron sub-assembly RH with the 5 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

  9. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand.

      If the coolant level goes down, add coolant.

    3. Install the radiator cap securely.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

    5. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    8. Stop the engine and wait until the coolant cools down.

    9. Remove the radiator cap and check the coolant level inside the radiator.

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  10. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), 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 leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.