CRANKSHAFT POSITION SENSOR INSTALLATION

TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH

1. 

   Temporarily install the compressor and magnetic clutch with the 3 bolts.

   Tip:

   Temporarily tighten the bolts in the order shown in the illustration.

INSTALL COMPRESSOR AND MAGNETIC CLUTCH

1. 

   Install the compressor and magnetic clutch with the 4 bolts.

   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.

2. Engage each clamp.

3. Connect each connector.

CONNECT SUCTION HOSE SUB-ASSEMBLY

1. Remove the attached vinyl tape from the hose.

2. Apply sufficient compressor oil 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 suction hose sub-assembly.

4. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

CONNECT DISCHARGE HOSE SUB-ASSEMBLY

1. Remove the attached vinyl tape from the hose.

2. Apply sufficient compressor oil 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 discharge hose sub-assembly.

4. Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR

1. 

   Install the radiator assembly and fan assembly with motor.

INSTALL COOLER CONDENSER ASSEMBLY

1. 

   Install the cooler condenser assembly with the 4 bolts.

   6.0 N*m

   61 kgf*cm

   53 in.*lbf

INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for LHD)

1. 

   Install the upper radiator support sub-assembly with the 6 bolts and attach the hood lock control cable clamp to the radiator support.

   Bolt A
   9.8 N*m	100 kgf*cm	87 in.*lbf

2. 

   Connect the low pitched horn and high pitched horn connectors.

INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for RHD)

1. 

   Install the upper radiator support sub-assembly with the 6 bolts and attach the hood lock control cable clamp to the radiator support.

   Bolt A
   9.8 N*m	100 kgf*cm	87 in.*lbf

2. 

   Connect the low pitched horn and high pitched horn connectors.

INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch)

1. 

   Apply MP grease to the sliding areas of the lock.

2. 

   Connect the hood lock control cable.

3. 

   Install the hood lock assembly with the 3 bolts.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

4. 

   Install the hood lock nut cap.

INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch)

1. 

   Apply MP grease to the sliding areas of the lock.

2. 

   Connect the hood lock control cable.

3. 

   Install the hood lock assembly with the 3 bolts.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

4. 

   Install the hood lock nut cap.

5. 

   Connect the connector.

INSTALL RADIATOR GRILLE

1. 

   Engage the 2 guides and 8 claws, and install the radiator grille sub-assembly.

2. Install the 6 clips.

CONNECT COOLING FAN ECU CONNECTOR

1. 

   Connect the cooling fan ECU connector and attach the wire harness clamps to the fan shroud RH side.

2. 

   Attach the wire harness clamps to the fan shroud LH side.

CONNECT OIL COOLER HOSE

1. 

   Connect the oil cooler hoses to the radiator.

CONNECT NO. 2 RADIATOR HOSE

1. 

   Connect the No. 2 radiator hose to the radiator.

CONNECT NO. 1 RADIATOR HOSE

1. 

   Connect the No. 1 radiator hose to the radiator.

INSTALL NO. 1 AIR CLEANER INLET

1. 

   Install the No. 1 air cleaner inlet with the 2 bolts.

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

   [A]

   5.0 N*m

   51 kgf*cm

   44 in.*lbf

   [B]

2. Connect the 2 vacuum hoses.

INSTALL NO. 2 AIR CLEANER INLET

1. 

   Install the No. 2 air cleaner inlet with the 2 bolts.

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

2. Connect the 2 vacuum hoses and harness clamps.

INSTALL BATTERY

1. 

   Install the battery tray and battery.

2. Install the battery clamp with the bolt and nut.

   Bolt
   5.4 N*m	55 kgf*cm	47 in.*lbf
   Nut A
   5.4 N*m	55 kgf*cm	47 in.*lbf

3. Connect the positive battery terminal, and tighten the nut.

   Nut B
   6.4 N*m	64 kgf*cm	57 in.*lbf

4. Connect the negative battery terminal, and tighten the nut.

   Nut C
   6.4 N*m	64 kgf*cm	57 in.*lbf

INSTALL COOL AIR INTAKE DUCT SEAL

1. 

   Install the cool air intake duct seal with the 11 clips.

CHARGE WITH REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

2. 

   Charge with refrigerant HFC-134a (R134a).

   Standard (w/o Rear Air Conditioning System)
   550 to 650 g (19.4 to 22.9 oz.)

   Standard (w/ Rear Air Conditioning System)
   720 to 820 g (25.4 to 28.9 oz.)

   09985-20010

   09985-02010

   09985-02050

   09985-02060

   09985-02070

   09985-02080

   09985-02090

   09985-02110

   09985-02130

   09985-02140

   09985-02150

   Note:
   

   • Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.

   • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

   Tip:

   Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block drain cock plug. (for Bank 1)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Tighten the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

4. Loosen the air drain cock plug on the water inlet housing.

5. 

   Loosen the air drain plug at the top of the radiator assembly 3 or 4 turns.

   Table 1. Text in Illustration

   *1	Air Drain Plug

6. Add engine coolant to the radiator inlet opening until engine coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

7. Continue to add engine coolant to the radiator inlet opening until engine coolant overflows from the radiator air drain hole. Then tighten the air drain plug.

   1.5 N*m

   15 kgf*cm

   13 in.*lbf

   Tip:

   If the engine coolant level at the radiator inlet opening drops after squeezing the No. 1 radiator hose and No. 2 radiator hose, add engine coolant.

8. Slowly fill the radiator assembly with engine coolant.

   Standard Capacity
   Condition Specified Condition w/ Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts) w/o Rear Heater 9.5 liters (10.1 US qts, 8.4 Imp. qts)

   Note:

   Never use water as a substitute for engine coolant.

   Tip:

   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).

9. Slowly pour engine coolant into the radiator reservoir tank until it reaches the full line.

10. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

    If the engine coolant level is low, add engine coolant.

11. Bleed air from the cooling system.

    
    

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

       Tip:

       The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

    2. Maintain the engine speed at 2500 to 3000 rpm.

    3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.

       CAUTION:

       When squeezing the No. 1 radiator hose and No. 2 radiator hose:

       
       

       • Wear protective gloves.

       • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

       • Keep your hands away from the fan and No. 2 fan.

       Note:
       

       • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

       • Make sure that the radiator reservoir tank still has some engine coolant in it.

       • If the radiator reservoir tank does not have enough engine coolant, the engine may overheat or be seriously damaged.

       • If the radiator reservoir tank does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reservoir tank is filled to the full line.

12. Stop the engine, and wait until the engine coolant cools down.

13. Add engine coolant to the full line on the radiator reservoir tank.

INSPECT FOR COOLANT LEAK

1. 

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

2. Warm up the engine.

3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.

   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.

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note:

   Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

INSPECT FOR REFRIGERANT LEAK

1. After recharging with refrigerant gas, inspect for refrigerant leak using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Make sure that the ignition switch is off.

   • 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. 

   Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines.

4. 

   Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.

   Tip:
   

   • 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 it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

5. If a gas leak is not detected from the drain hose, remove the blower motor from the cooling unit. Insert the gas leak detector 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.

INSTALL NO. 1 ENGINE UNDER COVER

1. 

   Install the No. 1 engine under cover with the 6 bolts and 2 clips.

INSTALL ENGINE UNDER COVER ASSEMBLY

1. 

   Install the engine under cover assembly with the 2 bolts, 2 screws and 5 clips.

2. 

   Install the engine under cover assembly RR with the 2 bolts.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

   Fit the 3 retainers and install the V-bank cover.