IGNITION COIL AND SPARK PLUG INSTALLATION

INSTALL NO. 1 SURGE TANK STAY

1. 

   Install the No. 1 surge tank stay with the bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

1. Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

2. 

   Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

   Bolt
   18 N*m	184 kgf*cm	13 ft.*lbf
   Nut
   16 N*m	163 kgf*cm	12 ft.*lbf

3. 

   Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

4. 

   Connect the connector to the intake air control valve assembly.

5. 

   Connect the 2 water by-pass hoses to the throttle body assembly.

6. 

   Connect the fuel vapor feed hose to the intake air surge tank assembly.

7. 

   Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

8. 

   Connect the ventilation hose.

9. Connect the union to connector tube hose.

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. 

   Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.

2. 

   Connect the air cleaner hose to the throttle body with the hose clamp.

3. Connect the ventilation hose.

4. 

   Connect the purge line hose.

5. Connect the 2 wire harness clamps and mass air flow meter connector.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the 2 cylinder block drain cock plugs.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Remove the reserve tank cap. (*1)

4. Loosen the air drain cock plug on the water inlet housing.

5. Add TOYOTA Super Long Life Coolant (SLLC).

   Standard capacity
   10.6 liters (11.2 US qts, 9.3 Imp. qts)

   Note:

   Never use water as a substitute for engine coolant.

   Tip:
   

   • 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).

   • Squeeze the No. 1 and No. 2 radiator hoses several times. If the coolant level at the water inlet opening drops, add TOYOTA SLLC.

6. Add TOYOTA SLLC to the reserve tank until coolant overflows from the air drain cock plug hole. Then tighten the air drain cock plug on the water inlet housing.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

7. 

   Continue adding TOYOTA SLLC until it reaches the B line. (*2)

8. Install the reserve tank cap. (*3)

9. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. (*4)

   CAUTION:
   
   

   • When push the radiator hoses, wear protective gloves.

   • Be careful as the radiator hoses, engine and radiator are hot.

   • Keep your hands away from the radiator fans.

   Note:
   

   • If the radiator reserve tank runs out of coolant just after the engine is started, stop the engine immediately, wait until the coolant has cooled down, and then add coolant.

   • Make sure that the reserve tank still has some coolant in it.

   • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

   • If there is not enough coolant, the engine may overheat or be seriously damaged.

   Tip:
   

   • 

     If coolant comes out from the bypass hose port connected to the reserve tank, the thermostat has been opened.

   • After the thermostat has opened, idle the engine until the coolant in the reserve tank goes from being cloudy to a clear red.

10. Stop the engine and wait until the coolant cools down. (*5)

11. 

    Check that the coolant level is between the FULL and LOW lines. (*6)

    Tip:
    

    • If the coolant level is below the LOW line, repeat steps from (*1) to (*6).

    • 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 ENGINE COOLANT LEAK

1. Remove the radiator reservoir cap.

   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.

2. 

   Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

3. Warm up the engine.

4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and water pump for leaks.

   If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

5. Reinstall the radiator reservoir cap.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

   Fit the 3 retainers and install the V-bank cover sub-assembly.

INSTALL RADIATOR COVER SUB-ASSY (for ALPHARD)

1. Install the radiator cover sub-assembly with the 4 clips.

INSTALL RADIATOR COVER SUB-ASSEMBLY (for VELLFIRE)

1. Install the radiator cover sub-assembly with the 4 clips.

INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY

1. 

   Install the outer cowl top panel with the 8 bolts.

   8.8 N*m

   90 kgf*cm

   78 in.*lbf

2. Connect the 2 clamps to the outer cowl top panel.

3. Remove the protective tape.

INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

1. 

   Install the brake master cylinder reservoir with bracket to the outer cowl top panel with the 2 nuts.

   6.5 N*m

   66 kgf*cm

   58 in.*lbf