EXHAUST PIPE GAS CONTROL ACTUATOR INSTALLATION

INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR

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*1	Exhaust Pipe Gas Control Actuator Case
*2	Exhaust Pipe Gas Control Stopper
*3	Exhaust Pipe Gas Control Actuator
*4	O-ring
*5	Piston

Apply engine coolant to the O-ring.

Install the exhaust pipe gas control actuator and exhaust pipe gas control stopper.
Note
- Be sure to install the exhaust pipe gas control stopper in the correct direction.
- Check that the O-ring is not deformed, cracked or swollen.
- Be sure to install the exhaust pipe gas control actuator until it touches the exhaust pipe gas control stopper.
- When installing the exhaust pipe gas control actuator, do not push on the piston.
- Make sure that the exhaust pipe gas control actuator and the exhaust pipe gas control stopper are free of oil.
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*1 Gasket

Install a new gasket and the exhaust pipe gas control actuator case with the 3 bolts and 3 nuts.

Torque:

5.0 N*m { 51 kgf*cm, 44 in.*lbf }
Note
- Be sure to install a new gasket in the correct direction.
- Make sure that the exhaust pipe gas control actuator case and the new gasket are free of oil.
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*1 Protective Tape

Using a screwdriver with the tip taped, pry the spring end to engage the spring.
Connect the 2 heater hoses.

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*1	Gasket

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*1	Protective Tape

ADD COOLANT (for Engine)

Tighten the radiator drain cock plug by hand.
Tighten the 2 cylinder block drain cock plugs.

Torque:

13 N*m { 130 kgf*cm, 9 ft.*lbf }
Loosen the air drain cock plug on the water inlet housing.
Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

Torque:

13 N*m { 130 kgf*cm, 9 ft.*lbf }

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Standard Capacity
Item	Capacity
Engine coolant	11.7 liters (12.4 US qts, 10.2 lmp. 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).
Contact your TOYOTA dealer for further details.

Note

Never use water as a substitute for engine coolant.

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*1 Full Line

Slowly pour coolant into the radiator reservoir tank until it reaches the full line.
Install the radiator cap.
Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.
Bleed air from the cooling system.
1. Put the engine in inspection mode Click here.
2. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
  
  Tech Tips
  
  The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
3. Maintain the engine speed at 2500 rpm.
4. Squeeze the inlet and No. 1 and No. 2 radiator hoses several times by hand to bleed air.
  CAUTION:
  
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the cooling fans.
  Note
  - Make sure that the radiator reservoir 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.
  - If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the Full line.
Stop the engine and wait until the engine coolant cools down.
Add engine coolant to the full line on the radiator reservoir.

INSTALL HEATER COVER
1. Install the heater cover with the 2 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
2. Connect the clamp.
INSTALL FRONT FLOOR COVER LH
1. Text in Illustration
  
  *1 Bolt
  
  *2 Screw
  
  Connect the 2 clips (B).
2. Install the front floor cover LH with the 2 screws and 4 bolts.
3. Install the clip (A).
INSPECT FOR COOLANT LEAK (for Engine)
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.

Note

Before performing each inspection, turn the A/C switch off.
1. Remove the radiator cap.
2. Fill the radiator with coolant and attach a radiator cap tester.
3. Put the engine in inspection mode Click here.
4. Warm up the engine.
5. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator, exhaust center pipe assembly and the heater hose around the water temperature switch and engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
6. Remove the radiator cap tester.
7. Install the radiator cap.
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Fit the 4 retainers and install the V-bank cover sub-assembly.
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 6 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover with the 4 clips.
INSTALL ENGINE ROOM SIDE COVER
1. Install the engine room side cover with the 4 clips.

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*1	Bolt
*2	Screw