THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A003B0FE01

      Install the thermostat with the jiggle valve facing up.

      Tech Tips

      The jiggle valve may be set within 15° on either side of the prescribed position.

  2. INSTALL WATER INLET


    1. A003G6NE01

      Install the water inlet with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  3. CONNECT ENGINE WIRE


    1. Connect the engine wire to the bracket.

  4. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

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

  5. INSTALL COMPRESSOR OUTLET ELBOW


    1. A003EV8E01

      Install the compressor outlet elbow with the 2 bolts and 2 clamps.

      Torque:
      Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  6. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Install the air cleaner hose assembly with the clamp.

  7. INSTALL AIR TUBE ASSEMBLY


    1. Install the air tube assembly with the 2 clamps and 2 bolts.

  8. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A003GDEE01

    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.

    2. Tighten the compressor and magnetic clutch with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  9. INSTALL FAN & GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  10. INSTALL FENDER APRON MUDGUARD SEAL RH

  11. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  12. INSTALL FRONT DOOR SCUFF PLATE RH

  13. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Click here

    Tech Tips

    Perform the same procedure as RH side on the LH side.

  14. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Click here

    Tech Tips

    Perform the same procedure as RH side on the LH side.

  15. CONNECT BATTERY NEGATIVE CABLE

  16. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)
      w/ Front Heater 14.2 liters (15.0 US qts, 12.5 Imp. qts)
      w/ Front and Rear Heaters 16.2 liters (17.1 US qts, 14.3 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants 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 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A003EJI

      Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A003FFY

      After the engine cools down, check that the engine coolant level is between the LOW and FULL level marks.

  17. CHECK FOR ENGINE COOLANT LEAKAGE

    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.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  18. INSTALL ENGINE UNDER COVER NO.1