THERMOSTAT INSTALLATION

INSTALL VANE PUMP ASSEMBLY

INSTALL FAN & GENERATOR V BELT

1. Install the drive belt to the pulleys except the drive belt tensioner pulley.

2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

   Note

   
   

   • The backside of the drive belt should face the tensioner pulley.

   • Check that the drive belt is properly set to each pulley.

3. 

   After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.

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 }

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block water drain cock plug.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

3. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

   Standard Capacity
   Item Specified Condition w/o Rear Heater 11.2 liters (11.8 US qts, 9.9 lmp. qts) w/ Rear Heater 13.2 liters (13.9 US qts, 11.6 lmp. qts)

   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).

4. Remove the 2-way that is located near the throttle body assembly.

5. When air is bled and the engine coolant drains out, install the 2-way.

6. Add coolant through the radiator reservoir assembly filter opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]

7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

   CAUTION:

   
   

   • Wear protective gloves.

   • Be careful as the radiator hoses are hot.

   • Keep your hands away from the radiator fans.

   Note

   
   

   • Immediately after starting the engine, if the radiator reservoir assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.

   • Do not start the engine when there is no engine coolant in the radiator reservoir assembly.

   • Make sure that the needle does not show an abnormally high temperature.

   • If there is not enough engine coolant, the engine may overheat.

   Tech Tips

   
   

   • Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.

   • The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

9. Check the engine coolant level in the radiator reservoir assembly. [*4]

   Tech Tips

   
   

   • If the engine coolant level is below the LOW line, repeat step *1 through *4.

   • If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW lines.

CHECK FOR ENGINE COOLANT LEAKS

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 or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.