THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT HOUSING


    1. Install a new gasket to the thermostat housing.

    2. A0135Z1

      Temporarily tighten the thermostat housing to the specified torque.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

    3. Fully tighten the 4 bolts to the specified torque.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A0136HO

      Install the engine coolant temperature sensor with a new clip.

  3. CONNECT WATER HOSE C


    1. A01390N

      Install the "torx" bolt, and connect the water hose C.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  4. CONNECT WATER HOSE B


    1. A0137E5

      Connect the water hose B with a new clamp.

  5. CONNECT WATER HOSE A


    1. A01369B

      Connect the water hose A.

  6. CONNECT RADIATOR HOSE NO.2


    1. A0137H9

      Connect the radiator hose No.2 with a new clamp.

  7. CONNECT RADIATOR HOSE


    1. A0138LZ

      Install the radiator hose with a new clamp.

  8. CONNECT WATER BY-PASS HOSE NO.2


    1. A0135YV

      Connect the water by-pass hose No.2 with a new hose clip.

  9. INSTALL INLET AIR CLEANER NO.2


    1. A0136IS

      Using a "torx" socket wrench, install the inlet air cleaner No.2 with the screw.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    2. A01390A

      Connect the mass air flow meter connector.

  10. INSTALL INLET AIR CLEANER


    1. A0137J3

      Install inlet air cleaner.

  11. INSTALL ENGINE ROOM RELAY BLOCK


    1. A013706E01

      Connect the 3 wire harness clamps.

    2. Engage the claw and install the engine room relay block with the 2 bolts.

      Torque:
      Bolt A
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      Bolt B
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  12. INSTALL BATTERY CARRIER


    1. A01368RE01

      Install the battery carrier with the 3 bolts.

      Torque:
      For A
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      For B
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  13. INSTALL BATTERY


    1. A01382G

      Install the battery and clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    2. Connect the positive battery cable.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. ADD ENGINE COOLANT


    1. A01375N

      Install the drain plug with an O-ring and a new clip.

    2. Connect the radiator hose No.2.

    3. Pour engine coolant into the reserve tank assembly.

      Capacity
      4.0 to 4.4 L

      Note

      Do not substitute water for engine coolant.

      Tech Tips


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

      • Use only Premium Long Life Coolant for 1WZ and 2WZ-TV. Pre-mixed. Green. 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. A0136NJ

      Connect the water by-pass hose with the hose clamp.

      Tech Tips

      Connect the water by-pass hose, when the fluid flows clean and without air bubbles.

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

    7. Install the reservoir tank cap sub-assembly securely.

  15. START THE ENGINE

  16. CHECK FOR ENGINE COOLANT LEAKS


    1. Start the engine.

    2. Maintain the engine speed at 1,500 rpm until the first cooling cycle (cooling fan on).

    3. Stop the engine and wait for cool down.

    4. If necessary top up the level to the maximum mark.

  17. INSTALL ENGINE UNDER COVER


    1. A013649

      Install the engine under cover with the 5 screws.

    2. Install the 9 bolts.