THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT


    1. Install a new gasket onto the thermostat.

    2. A0135Y4

      Install the thermostat to the water inlet aligning with the location of the cylinder head and the jiggle pin of the thermostat as shown in the illustration.

  2. INSTALL WATER INLET


    1. A0136AG

      Install the water inlet to the cylinder block with the 2 bolts.

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

      Note


      • Avoid catching the rubber gasket of thermostat under the water inlet.

      • Do not use a water inlet that has been dropped.

      • Ensure that gasket is stuck between the water inlet and block.

    2. Connect the radiator outlet hose to the water inlet with the clip.

  3. ADD ENGINE COOLANT


    1. Connect the engine side radiator outlet hose .

    2. A0137DX

      Install the cylinder block drain cock plug.

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

    3. Pour engine coolant into the radiator assembly until it is full.

      Capacity
      Specification Capacity
      except Tropic Spec 4.0 liters (4.2 US qts, 3.5 Imp qts)
      for Tropic Spec 4.4 liters (4.6 US qts, 3.9 Imp qts)

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. Install the radiator cap sub-assembly securely.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. 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.

      2. The thermostat open timing can be confirmed by pressing the outlet radiator hose by hand, and checking when the coolant starts to flow inside the hose.

      3. Maintain the engine speed at 2500 to 3000 rpm and warm up the engine until the cooling fan operates.

      4. Press the outlet radiator hose and inlet radiator hose several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

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

    9. If the engine coolant level is below the full level, perform steps (c) through (h) and repeat the operation until the engine coolant level stays the full level.

    10. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.

  4. START THE ENGINE

  5. CHECK FOR ENGINE COOLANT LEAKS

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375K

      Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

    2. Warm up the engine.

    3. Pump it to 137 kpa (1.4 kgf*cm2, 19.9 psi), then check that the pressure does not drop.


      • If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.

    4. Be sure not to put more than 177 kpa (1.8 kgf*cm2, 25.6 psi).