RADIATOR INSTALLATION

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 4 guides and 6 claws, and install the radiator grille.

2. 

   Install the 4 clips and 2 bolts.

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.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the 2 cylinder block drain cock plugs.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

   for cylinder block drain cock plugs

3. Loosen the air drain cock plug from the water inlet housing.

4. 

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

5. 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.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

   for air drain cock plug

6. 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.

   1.5 N*m

   15 kgf*cm

   13 in.*lbf

   for air drain plug

   Tip:

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

7. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Standard capacity
   Table 1. w/o Engine oil cooler Condition Specified Condition w/ Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts) w/o Rear Heater 8.8 liters (9.3 US qts, 7.7 Imp. qts)
   Table 2. w/ Engine oil cooler 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)

   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 consists of a combination of low phosphates and organic acids).

   • Contact your TOYOTA dealer for further details.

   Note:

   Never use water as a substitute for engine coolant.

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

9. 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.

10. Bleed air from the cooling system.

    
    

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

       Tip:

       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.

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

    3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.

       CAUTION:

       When squeezing the radiator hoses:

       
       

       • Wear protective gloves.

       • Be careful as the radiator hoses are hot.

       • Keep your hands away from the radiator fan.

       Note:
       

       • 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.

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

12. Add engine coolant to the FULL line on the radiator reservoir.

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.

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.