INTERCOOLER INSTALLATION

INSTALL INTERCOOLER ASSEMBLY
1. Connect the No. 1 vacuum transmitting hose to the intercooler.
INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY
1. Install the lower radiator support RH with the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Attach the clamp to the vacuum transmitting pipe, and then install the lower radiator support LH with the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
INSTALL NO. 2 AIR TUBE
1. Install the No. 2 air tube with the bolt.
  
  Torque:
  
  31 N*m { 316 kgf*cm, 23 ft.*lbf }
  
  Note
  
  Before installation, remove any oil residue from the inside of the pipe and hose.
2. Tighten the hose clamp.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Connect the air temperature sensor connector.
INSTALL RADIATOR ASSEMBLY
1. Install the 2 radiator lower support cushions.
2. Insert the radiator with intercooler while holding it at an angle to install it as shown in the illustration.
  
  Note
  
  w/ Air Conditioning System:
  
  Do not apply any excessive force to the cooler pipe when installing the radiator assembly.
3. Connect the No. 2 vacuum transmitting hose.
INSTALL CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)
1. Install the condenser assembly with receiver as shown in the illustration.
  
  Tech Tips
  
  If the condenser is replaced with a new one, add compressor oil to a new condenser.
  
  Capacity
  
  40 cc (1.4 fl.oz)
  
  Compressor oil
  
  ND-OIL 8 or equivalent
INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
1. Install the radiator support with the 4 bolts.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL HOOD LOCK ASSEMBLY
1. Install the hood lock with the 3 bolts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
2. Connect the hood lock control cable.
3. w/ Engine Hood Courtesy Switch:
  
  Attach the clamp and connect the hood lock courtesy switch connector.
INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY
1. Install the 2 upper radiator supports with the 4 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Install the 2 radiator support cushions.
INSTALL UPPER RADIATOR SUPPORT
1. Install the 2 upper radiator supports with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Air Conditioning System)
1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the suction pipe sub-accessory assembly.
4. Connect the suction pipe sub-assembly to the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
1. Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the discharge hose sub-assembly.
4. Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }

Capacity
40 cc (1.4 fl.oz)

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

INSTALL NO. 3 AIR HOSE

Note

Before installation, remove any oil residue from the inside of the throttle body and tube.

Text in Illustration
*1	Embossed Mark
*2	Paint Mark
*a	Rear
*b	RH Side

Align the paint mark of the No. 3 air hose with the embossed mark of the throttle body.

Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.
Tighten the clamp of the No. 3 air hose on the diesel throttle body side.

Torque:

6.5 N*m { 66 kgf*cm, 58 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
- Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).
Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

Torque:

6.5 N*m { 66 kgf*cm, 58 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
- Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

INSTALL INTERCOOLER AIR HOSE
Note
- Check that the retainer is closed when the connector is inserted.
- If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.
- If replacing the hose, apply fresh oil to the O-ring.
- Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.
- Do not use a quick connector that has been dropped.
1. Text in Illustration
  
  *1 Retainer
  
  Install the intercooler air hose to the intercooler and No. 1 air tube and push in the retainer.
2. Tighten the hose clamp.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }

Text in Illustration
*1	Retainer

INSTALL NO. 2 RADIATOR HOSE

Text in Illustration
*1	Match Mark
*a	View A
*b	View B
*c	Top
*d	LH Side
*e	RH Side

Connect the No. 2 radiator hose.

Tech Tips

Position the clips as illustrated.

INSTALL NO. 1 RADIATOR HOSE

Text in Illustration
*1	Match Mark
*a	View A
*b	View B
*c	Top
*d	RH Side

Connect the No. 1 radiator hose.

Tech Tips

Position clips A and B as Illustrated.

INSTALL INJECTOR DRIVER
1. Install the injector driver bracket with the 4 screws.
  
  Torque:
  
  2.0 N*m { 20 kgf*cm, 18 in.*lbf }
2. Install the injector driver with the 3 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
3. Attach the clamp and connect the 4 connectors.
CONNECT NO. 1 WATER HOSE CLAMP BRACKET
1. Connect the No. 1 water hose clamp bracket to the radiator support with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Attach the 2 hose clamps to the No. 2 by-pass water hose, and then connect the No. 1 radiator hose to the No. 1 water hose clamp bracket.
INSTALL NO. 3 WATER BY-PASS HOSE
1. Connect the 3 connectors and attach the clamp.
2. Install the No. 3 water by-pass hose and attach the clamp.
INSTALL RADIATOR SIDE DEFLECTOR LH
INSTALL RADIATOR SIDE DEFLECTOR RH
INSTALL RADIATOR GRILLE BRACKET
1. Install the radiator grille bracket with the 2 bolts and nut.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL HORN ASSEMBLY
1. Install the horn with the bolt.
  
  Torque:
  
  20 N*m { 199 kgf*cm, 14 ft.*lbf }
2. Connect the 2 horn connectors.
CONNECT AMBIENT THERMISTOR ASSEMBLY (w/ Air Conditioning System)
1. Attach the clamp to connect the ambient thermistor.
INSTALL BATTERY CARRIER
1. Install the battery carrier with the 4 bolts.
  
  Torque:
  
  19 N*m { 189 kgf*cm, 14 ft.*lbf }
2. Attach the 2 clamps to connect the wire harness.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY CLAMP SUB-ASSEMBLY
1. Attach the hook of the battery clamp to the battery carrier.
2. Partially tighten the nut and temporarily install the bolt.
3. Adjust the battery clamp position.
4. Tighten the nut and bolt.
  
  Torque:
  
  for bolt
  
  17 N*m { 168 kgf*cm, 12 ft.*lbf }
  
  for nut
  
  3.5 N*m { 36 kgf*cm, 31 in.*lbf }
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
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

Tighten the radiator drain cock plug by hand.

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Standard Capacity

Item	Specified Condition
w/o Power Heater	7.4 liters (7.8 US qts, 6.5 Imp. qts)
w/ Power Heater	7.8 liters (8.2 US qts, 6.9 Imp. qts)

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 is a combination of low phosphates and organic acids).

Note

Never use water as a substitute for engine coolant.

Text in Illustration

*1 Air Release Plug

Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.
Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.
Install the cap and air release plug, and warm up the engine sufficiently.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
Note
- Before starting the engine, turn the A/C switch off.
- Adjust the air conditioning temperature setting to MAX (HOT).
- Adjust the air conditioning blower setting to Lo.
1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
  
  Tech Tips
  
  The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand and sensing vibrations when the engine coolant starts to flow inside the hose.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
2. After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern at least 8 times).
3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
After the engine has cooled down, check that the coolant level is between FULL and LOW.

If the coolant level is low, add coolant until the coolant level reaches the reservoir tank FULL line.

CHARGE REFRIGERANT (w/ Air Conditioning System)
SST

09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )
1. Perform vacuum purging using a vacuum pump.
2. Charge refrigerant HFC-134a (R134a).
  
  Standard
  
  440 +/-30 g (15.5 +/-1.1 oz)
  Note
  
  Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
  
  Approximately 200 g (7.05 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
WARM UP ENGINE (w/ Air Conditioning System)
1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
  
  Note
  
  Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

Text in Illustration
*1	Air Release Plug

Standard
440 +/-30 g (15.5 +/-1.1 oz)

INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation observing the following instructions:
- Stop the engine.
- Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
- Repeat the test 2 or 3 times.
- Make sure that some refrigerant remains in the refrigeration system.
  
  Tech Tips
  
  When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm², 57 to 85 psi).

Text in Illustration
*1	Check for Leakage
*2	Halogen Leak Detector

Using a halogen leak detector, check the refrigerant line for leakage.

If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

INSPECT FOR COOLANT LEAK
1. Remove the radiator reservoir cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
2. Fill the radiator 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 leakage.
  
  If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
5. Reinstall the radiator reservoir cap.
INSTALL RADIATOR SUPPORT OPENING COVER
1. Install the radiator support opening cover with the 7 clips.
INSTALL NO. 1 ENGINE COVER
1. Attach the 4 clips to install the No. 1 engine cover.
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 11 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
1. Insert the 2 hooks of the front lower bumper absorber into the installation holes on the body to install the front lower bumper absorber.
2. Install 8 bolts and 3 screws.
3. Install the 4 screws and 2 bolts.