THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT

    A01BHU2E09

    1. Install a new gasket onto the thermostat.

      Tech Tips

      When installing the thermostat onto 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° on either side of the prescribed position.

  2. INSTALL WATER INLET


    1. Install the water inlet with the 3 bolts.

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

  3. CONNECT ENGINE WIRE (w/ DPF)


    1. A01BCTDE01

      Connect the engine wire with the 2 bolts.

      Torque:
      for bolt A
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      for bolt B
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Connect the 2 connectors.

  4. CONNECT NO. 4 RADIATOR HOSE

  5. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BFC7E01

      Install the V-ribbed belt tensioner with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Firmly press and hold the tensioner against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

  6. INSTALL GENERATOR ASSEMBLY


    1. Install the generator with the bolt.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  7. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the 2 bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  8. INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Install the No. 2 idle pulley assembly and washer with the bolt.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  9. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE02

      Temporarily install the No. 1 compressor mounting bracket with the 4 bolts.

      Tech Tips

      Make sure that the No. 1 compressor mounting bracket is in contact with the cylinder block.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A01BFJ0E01

    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.

    2. Tighten the compressor and magnetic clutch with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  11. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

    A01BDO5

    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the cooler refrigerant suction hose.

    4. Install the cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  12. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

    A01BGYM

    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the cooler refrigerant discharge hose.

    4. Install the cooler refrigerant discharge hose onto the compressor and magnetic clutch with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  13. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BFP8E01

      Install the compressor outlet elbow with the 2 hose clamps and bolt.

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for hose clamp A
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      for hose clamp B
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  14. INSTALL COMPRESSOR ELBOW STAY


    1. Install the compressor elbow stay with the 2 bolts.

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

  15. INSTALL AIR TUBE ASSEMBLY


    1. A01BHAOE01

      Install the air tube and No. 1 air cleaner hose with the 2 bolts.

      Torque:
      for bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Tighten the 2 hose clamps.

  16. CONNECT NO. 1 AIR CLEANER HOSE


    1. Connect the No. 1 air cleaner hose to the compressor inlet elbow.

      Note

      Pull the hose to make sure that it is locked and securely connected.

  17. INSTALL FAN AND GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  19. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.6 liters (14.4 US qts, 12.0 Imp. qts)
      w/ Front Heater 14.6 liters (15.4 US qts, 12.8 Imp. qts)
      w/ Front and Rear Heaters 16.6 liters (17.5 US qts, 14.6 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.

    6. 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.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  20. CHARGE REFRIGERANT (w/ Air Conditioning System)


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01BFDKE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  21. INSPECT FOR COOLANT LEAK

    CAUTION:

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


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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  22. INSPECT REFRIGERANT LEAK (w/ Air Conditioning System)


    1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A01BC1LE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. A01BCXGE01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

  23. INSTALL FENDER APRON MUDGUARD SEAL RH


    1. Engage the 3 clips and install the fender apron mudguard seal RH.

  24. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

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

  25. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  26. INSTALL FRONT DOOR SCUFF PLATE RH


    1. Engage the 5 clips and install the front door scuff plate RH.

  27. INSTALL NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 1 engine under cover with the 4 bolts.

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