Install a new gasket to the thermostat.
Install the thermostat with the jiggle valve facing up.
The jiggle valve may be set within 10° on either side of the prescribed position.
INSTALL WATER INLET
Install the water inlet with the 2 nuts .
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
Install the idler pulley cover plate and idler pulley sub-assembly with the bolt.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the engine.
INSTALL V-RIBBED BELT
Install the V-ribbed belt.
Using SST, turn the V-ribbed belt tensioner assembly counterclockwise and remove the bar.
If it is difficult to install the V-ribbed belt, perform the following procedure:
Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.
Release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, and put the V-ribbed belt on the V-ribbed belt tensioner assembly pulley.
Put the backside of the V-ribbed belt on the V-ribbed belt tensioner assembly pulley and No. 2 idler pulley sub-assembly.
Check that the V-ribbed belt is properly set to each pulley.
After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the V-ribbed belt has not slipped out of the grooves on the bottom of the crankshaft pulley by hand.
INSTALL FRONT FENDER APRON SEAL RH
Install the front fender apron seal RH with the 2 bolts and clip.
INSTALL FRONT FENDER LINER RH
Install the front fender liner RH with the 5 clips and 8 screws.
Install the bolt.
Install 3 new grommets.
Using a 4 mm hexagon wrench, install the 2 screws.
Install the screw and 2 pin hold clips.
Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is aligned vertically.
INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH
Use the same procedures for the RH side and LH side Click here.
INSTALL FRONT WHEEL RH
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Tighten the 2 cylinder block drain cock plugs.
Loosen the air drain cock plug from the water inlet housing.
Loosen the air drain plug at the top of the radiator 3 or 4 turns.
Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.
Continue to add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the radiator air drain hole. Then close the air drain plug at the top of the radiator.
If the coolant level at the radiator inlet opening drops after squeezing the No. 1 and No. 2 radiator hoses, add coolant.
Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).
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).
Contact your TOYOTA dealer for further details.
Never use water as a substitute for engine coolant.
Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.
Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.
Bleed air from the cooling system.
Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Maintain the engine speed at 2500 to 3000 rpm.
Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.
When squeezing the radiator hoses:
Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fan.
Make sure that the radiator reservoir still has some coolant in it.
If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
If there is not enough coolant, the engine may overheat or be seriously damaged.
If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.
Stop the engine and wait until the engine coolant cools down.
Add engine coolant to the FULL line on the radiator reservoir.
INSPECT FOR COOLANT LEAK
Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Before performing each inspection, turn the A/C switch off.
Fill the radiator with coolant and attach a radiator cap tester.
Warm up the engine.
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.
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 6 bolts and 2 clips.
INSTALL ENGINE UNDER COVER ASSEMBLY
Install the engine under cover assembly with the 2 bolts, 2 screws and 5 clips.
Install the engine under cover assembly RR with the 2 bolts.
INSTALL V-BANK COVER SUB-ASSEMBLY
Fit the 3 retainers and install the V-bank cover.