THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT


    1. A003HYTE01
      Text in Illustration
      *1 Gasket
      *a CORRECT
      *b INCORRECT

      Install a new gasket to the thermostat as shown in the illustration.

      Note

      When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed to the thermostat as shown in the illustration.

    2. A003AV4E01
      Text in Illustration
      *a Upward
      *b 30°
      *c Jiggle Valve

      Insert the thermostat into the engine water pump assembly with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set to within 30° on either side of the prescribed position.

  2. INSTALL WATER INLET


    1. Install the water inlet to the engine water pump assembly with the 2 bolts.

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

  3. CONNECT NO. 4 RADIATOR HOSE


    1. A003GNGE01
      Text in Illustration
      *a Upper Side
      *b Right Side of Vehicle

      Connect the No. 4 radiator hose to the water inlet and slide the hose clamp to secure the hose as shown in the illustration.

  4. CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the No. 2 water by-pass pipe sub-assembly to the engine water pump assembly and water inlet with the 2 bolts.

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

  5. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Connect the water hose sub-assembly to the No. 1 water by-pass pipe, and slide the hose clamp to secure the hose.

    2. Connect the water hose sub-assembly to the No. 2 water by-pass pipe sub-assembly, and slide the hose clamp to secure the hose.

  6. TEMPORARILY INSTALL FAN PULLEY


    1. Temporarily install the fan pulley and water pump spacer to the engine water pump assembly with the 4 nuts.

  7. TIGHTEN FAN PULLEY


    1. Tighten the 4 nuts and install the fan pulley.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  8. INSTALL FAN AND GENERATOR V BELT


    1. Set the fan and generator V belt onto each part.

      Tech Tips

      When installing the fan and generator V belt, attach the fan and generator V belt to the No. 1 idler pulley sub-assembly last.

    2. While turning the V-ribbed belt tensioner assembly clockwise, remove the pin.

    3. Check that the fan and generator V belt fits properly in the ribbed grooves.

      Note

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

  9. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. Connect the vane pump oil reservoir assembly to the body with the 2 nuts.

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

  10. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

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

      Standard capacity
      13.9 liters (14.6 US qts, 12.2 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 (SLLC) 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 water outlet sub-assembly.

    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 reserve tank assembly and install the radiator 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 line.

  11. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine assembly and radiator assembly are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator assembly 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 assembly 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 assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block sub-assembly and cylinder head sub-assembly.

  12. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

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

    2. Return the floor carpet to its original position.

  13. INSTALL FRONT SEAT ASSEMBLY RH


    1. A003GD3

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  14. INSTALL SEAT TRACK COVER LH


    1. A003B84

      Attach the claw and install a new seat track cover LH with a new clip.

  15. INSTALL FRONT DOOR SCUFF PLATE RH


    1. Attach the 5 clips and install the front door scuff plate RH.