GENERATOR INSTALLATION

INSTALL GENERATOR ASSEMBLY
1. Temporarily install the generator with the 2 stud bolts.
2. Using an E7 "TORX" socket wrench, tighten the 2 stud bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
3. Install the 2 nuts and 3 bolts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Install the the No. 1 intake air connector pipe to the No. 1 inlet compressor elbow.
5. Install the No. 1 intake air connector bracket with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Install the bolt to the No. 1 intake air connector pipe. Then tighten the hose clamp.
  
  Torque:
  
  for bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for hose clamp
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
7. Connect the wire harness bracket to the belt tensioner with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
8. 130 A Type and 150 A Type:
  
  Connect the generator wire with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
9. 180 A Type:
  
  Connect the generator wire with the nut.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
10. Install the terminal cap.
11. Connect the 6 wire harness clamps.
12. Connect the 4 connectors.
INSTALL NO. 1 AIR TUBE ASSEMBLY
1. Apply a light coat of washer fluid to a new O-ring and install it to the No. 1 air tube.
2. Install the No. 1 air tube with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY
1. Connect the No. 1 air cleaner pipe to the No. 1 intake air connector pipe.
2. Install the pipe with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)
1. Connect the 4 water hose ends, and install the water pipe with the 4 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL NO. 3 AIR TUBE
1. Text in Illustration
  
  *1 Paint Mark
  
  *a Top
  
  Install the No. 3 air tube with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
  
  Tech Tips
  
  Make sure the direction of the hose clamp is as shown in the illustration.
3. Install the wire harness bracket with the bolt.
4. Install the ground wire with the nut, and attach the wire harness clamp.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }

Text in Illustration
*1	Paint Mark
*a	Top

INSTALL NO. 1 AIR HOSE

Text in Illustration
*1	Protrusion
*2	Paint Mark
*a	Top

Connect the No. 1 air hose with the hose clamp.

Torque:: 6.3 N*m { 64 kgf*cm, 56 in.*lbf }

Tech Tips

Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).
Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).
Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL INTAKE AIR CONNECTOR
1. Connect the intake air connector to the No. 1 and No. 2 air cleaner pipes.
2. Install the connector with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Tighten the 2 hose clamps.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
4. Attach the 3 wire harness clamps.
5. w/o Viscous Heater:
  
  Connect the connector to the water temperature sensor.
6. w/ Viscous Heater:
  
  Connect the 2 connectors to the water temperature sensor and viscous with magnet clutch heater.
TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE
1. Temporarily install the air cleaner hose to the intake air connector.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Connect the air cleaner cap to the air cleaner hose, and install the air cleaner cap with the 4 clamps.
2. Connect the mass air flow meter connector and attach the wire harness clamp to the air cleaner cap.
3. Attach the wire harness clamp.
4. Align the protrusion of the air cleaner cap and the concave portion of the air cleaner hose.
5. Tighten the 2 hose clamps.
  
  Torque:
  
  2.5 N*m { 25 kgf*cm, 22 in.*lbf }
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the No. 2 engine oil level dipstick guide.
3. Install the No. 2 engine oil level dipstick guide with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Connect the ventilation hose to the cylinder head cover RH.
5. Connect the wire harness clamp to the No. 2 engine oil level dipstick guide bracket.
CONNECT WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)
1. Connect the 2 water hoses.

INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

Text in Illustration
*1	Protrusion
*a	Front
*b	LH Side

Install a new gasket to the air tube LH.

Tech Tips

Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 2 cool air inlet with the 3 nuts and bolt.

Torque:

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

Text in Illustration
*1	Protrusion
*2	Paint Mark
*a	Top

Connect the No. 2 air hose to the No. 2 cool air inlet.

Tighten the No. 2 air hose clamp.

Torque:

6.3 N*m { 64 kgf*cm, 56 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).
- Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).
- Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

Text in Illustration
*1	Protrusion
*a	Front
*b	RH Side

Install a new gasket to the air tube RH.

Tech Tips

Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 1 cool air inlet with the 3 nuts and bolt.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the vacuum hose, intake air temperature sensor connector and turbo pressure sensor connector.

Text in Illustration
*1	Protrusion
*2	Paint Mark
*a	Top

Connect the No. 1 air hose to the No. 1 cool air inlet.

Tighten the No. 1 air hose clamp.

Torque:

6.3 N*m { 64 kgf*cm, 56 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).
- Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).
- Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

Click here
INSTALL V-RIBBED BELT
1. Attach a wrench to the V-ribbed belt tensioner bracket and turn the wrench clockwise.
2. Install the V-ribbed belt as shown in the illustration.
3. Check that the belt fits properly in the ribbed grooves.
  
  Tech Tips
  
  Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
  
  If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.
INSTALL NO. 3 IDLER PULLEY (w/ Viscous Heater)
1. Align the No. 3 idler pulley bracket knock pin and No. 1 idler pulley bracket knock pin hole and install the No. 3 idler pulley with the nut.
  
  Torque:
  
  88 N*m { 898 kgf*cm, 64 ft.*lbf }
INSTALL NO. 1 IDLER PULLEY (w/ Viscous Heater)
1. Install the collar, No. 1 idler pulley and cover with the bolt.
  
  Torque:
  
  49 N*m { 495 kgf*cm, 36 ft.*lbf }

INSTALL V-RIBBED BELT (w/ Viscous Heater)

Install the V-ribbed belt as shown in the illustration.
Temporarily install the lock nut, and turn the bolt clockwise.

Text in Illustration
*a	Measuring Point

Using a belt tension gauge, inspect the belt tension.

Standard Belt Tension

Item	Condition	Specified Condition
New belt	5 to 35°C (41 to 95°F)	550 to 800 N (56 to 82 kgf, 123.6 to 179.8 lbf)
Used belt	5 to 35°C (41 to 95°F)	300 to 500 N (31 to 51 kgf, 67.4 to 112.4 lbf)

Tech Tips

When measuring the tension of a new belt, measure the tension immediately after installing it to the engine but before starting the engine.
A "new belt" is a belt which has been used for less than 5 minutes on a running engine.
A "used belt" is a belt which has been used on a running engine for 5 minutes or more.
After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension.

Tighten the nut.

Torque:

40 N*m { 408 kgf*cm, 30 ft.*lbf }
Check that the belt fits properly in the ribbed grooves.

Tech Tips

Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

ADD ENGINE COOLANT

Remove the engine air bleed cap.
Connect a clear hose to the engine air bleed pipe.
Using a wrench, remove the vent plug.

Fill the radiator with TOYOTA SLLC to the radiator reservoir filler neck.

Tech Tips

Pour TOYOTA SLLC until it spills out of the engine air bleed pipe.

Standard Capacity (for Automatic Transmission)

Item	Specified Condition
Front heater only	14.8 liters (15.6 US qts, 13.0 Imp. qts)
Front heater and rear heater	17.6 liters (18.6 US qts, 15.5 Imp. qts)
Front heater with viscous heater	15.2 liters (16.1 US qts, 13.4 Imp. qts)
Front heater and rear heater with viscous heater	18.0 liters (19.0 US qts, 15.4 Imp. qts)

Standard capacity (for Manual Transmission)
15.4 liters (16.3 US qts, 13.5 Imp. qts)

Note

Do not substitute plain water 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 consists of a combination of low phosphates and organic acids).

Install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }

Note

Do not tighten the plug to 5.0 N*m (51 kgf*cm, 44 in.*lbf) or more, as the plug will be damaged.
Disconnect the clear hose from the engine air bleed pipe.
Install the engine air bleed cap when coolant comes out.
Install the radiator reservoir cap.
Start the engine.

Note

Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line.
Maintain an engine speed of 3000 rpm for approximately 10 minutes so that the thermostat opens and air bleeding is performed.
CAUTION:
- Wear protective gloves.
- Be careful as the radiator hoses are hot.
- Keep your hands away from the radiator fan
Note
- Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
- If there is not enough coolant, the engine may burn out or overheat.
Tech Tips

The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Stop the engine, and wait until the engine coolant cools down to ambient temperature.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Check that the coolant level is between the FULL and LOW lines.

If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.

INSPECT FOR COOLANT LEAK
CAUTION:

Do not remove the radiator reservoir 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 reservoir.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 17.8 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 cylinder block and cylinder head.
INSTALL FRONT FENDER APRON SEAL REAR RH
1. Install the front fender apron seal rear RH with the 4 clips.
INSTALL FRONT FENDER APRON SEAL FRONT RH
1. Install the front fender apron seal front RH with the 3 clips.
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
1. Install the No. 1 engine under cover with the 10 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
1. Push in the clip to install the front fender splash shield sub-assembly LH.
2. Install the 3 bolts and screw.
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
1. Push in the clip to install the front fender splash shield sub-assembly RH.
2. Install the 3 bolts and 2 screws.