GENERATOR INSTALLATION


  1. INSTALL GENERATOR ASSEMBLY


    1. A017BV6

      Install the wire harness clamp bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A017FOZ

      Connect the generator bracket with the wire harness clamp.

    3. A017CS4

      Install generator assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    4. A017D5C

      Temporarily install the 2 bolts.

    5. A017D5C

      Fully tighten the 2bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A017FW6

      Connect the generator connector to the generator assembly.

    7. Install the generator wire with the nut.

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

    8. Install the terminal cap.

    9. Connect the 3 wire harness clamps.

    10. Connect the magnetic clutch connector to the compressor and magnetic clutch.

  2. INSTALL V-RIBBED BELT


    1. A017F8UE01

      Install the V-ribbed belt.

    2. Using SST, turn the V-ribbed belt tensioner assembly counterclockwise and remove the bar.

      SST
      09961-00950
    3. A017CTEE01

      If it is difficult to install the V-ribbed belt, perform the following procedure:


      1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.

      2. 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.

        Note


        • 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.

      3. 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.

  3. INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.

    4. A017BP5

      Install the No. 2 oil level dipstick guide with the bolt.

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

  4. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR


    1. A017D0H

      Install the radiator assembly and fan assembly with motor.

  5. INSTALL COOLER CONDENSER ASSEMBLY


    1. A017CEX

      Install the cooler condenser assembly with the 4 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  6. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for LHD)


    1. A017BFP

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

      Torque:
      Bolt A
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A017FE9

      Connect the low pitched horn and high pitched horn connectors.

  7. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for RHD)


    1. A017BD3

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

      Torque:
      Bolt A
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A017FE9

      Connect the low pitched horn and high pitched horn connectors.

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


    1. A017DH9

      Apply MP grease to the sliding areas of the lock.

    2. A017DBV

      Connect the hood lock control cable.

    3. A017CPZ

      Install the hood lock assembly with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A017D3E

      Install the hood lock nut cap.

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


    1. A017EIN

      Apply MP grease to the sliding areas of the lock.

    2. A017BQ6

      Connect the hood lock control cable.

    3. A017CI6

      Install the hood lock assembly with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A017FVJ

      Install the hood lock nut cap.

    5. A017EVU

      Connect the connector.

  10. INSTALL RADIATOR GRILLE SUB-ASSEMBLY


    1. A017F4G

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

    2. Install the 6 clips.

  11. CONNECT COOLING FAN ECU CONNECTOR


    1. A017DKS

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

    2. A017FVV

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

  12. CONNECT OIL COOLER HOSE


    1. A017F5B

      Connect the oil cooler hoses to the radiator.

  13. CONNECT NO. 2 RADIATOR HOSE


    1. A017FFS

      Connect the No. 2 radiator hose to the radiator.

  14. CONNECT NO. 1 RADIATOR HOSE


    1. A017EYO

      Connect the No. 1 radiator hose to the radiator.

  15. INSTALL NO. 1 AIR CLEANER INLET


    1. A017C2QE01

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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf, [A] }
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf, [B] }

    2. Connect the 2 vacuum hoses.

  16. INSTALL NO. 2 AIR CLEANER INLET


    1. A017D82

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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the 2 vacuum hoses and harness clamps.

  17. INSTALL BATTERY

    Note

    When reconnected the cable, some systems need to be initialized. Click here.


    1. A017FMCE02

      Install the battery tray and battery.

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

      Torque:
      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.

      Torque:
      Nut B
      6.4 N*m  { 64 kgf*cm, 57 in.*lbf }

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

      Torque:
      Nut C
      6.4 N*m  { 64 kgf*cm, 57 in.*lbf }

  18. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A017CN1

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

  19. INSTALL FRONT FENDER APRON SEAL RH


    1. A017FOB

      Install the front fender apron seal RH with the 2 bolts and clip.

  20. INSTALL FRONT FENDER LINER RH


    1. A017CFW

      Install the front fender liner RH with the 5 clips and 8 screws.

    2. Install the bolt.

    3. A017CZV

      Install 3 new grommets.

    4. Using a 4 mm hexagon wrench, install the 2 screws.

    5. A017FP4E01
      Text in Illustration
      *1 Correct
      *2 Incorrect

      Install the screw and 2 pin hold clips.

      Note

      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.

  21. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedures for the RH side and LH side Click here.

  22. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

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

      Torque:
      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)

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

    5. A017G9AE03
      Text in Illustration
      *1 Air Drain Plug

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

    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.

      Torque:
      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.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

      Tech Tips

      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.

      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).

    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.

        Tech Tips

        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.

  23. INSPECT FOR COOLANT LEAK

    CAUTION:

    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.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. A017G83

      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.

  24. INSPECT AUTOMATIC TRANSAXLE FLUID

    Tech Tips

    Click here.

  25. INSPECT FOR OIL LEAK

  26. INSTALL NO. 1 ENGINE UNDER COVER


    1. A017D1W

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

  27. INSTALL ENGINE UNDER COVER ASSEMBLY


    1. A017FXN

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

    2. A017FPR

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

  28. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  29. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A017EFM

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