THERMOSTAT INSTALLATION

CONNECT NO. 2 RADIATOR HOSE

1. Connect the No. 2 radiator hose with the hose clip.

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

   Torque:

   54 N*m  { 550 kgf*cm, 40 ft.*lbf }

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Close the cylinder block drain cock plug (for Bank 1).

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

3. Close the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until engine 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 }

6. 

   Text in Illustration

   *a

   Code Mark

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

   Specified capacity

   Code Mark "K"	8.8 liters (9.3 US qts, 7.7 lmp. qts)
   Code Mark "J"	8.9 liters (9.4 US qts, 7.8 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).

7. Remove the reserve tank cap.

8. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the engine coolant.

   If the engine coolant level is low, add engine coolant.

10. Install the radiator cap sub-assembly and reserve tank cap.

11. Bleed air from the cooling system.

    Note

    
    

    • Before starting the engine, turn the A/C switch off.

    • Adjust the heater control to the maximum hot setting.

    • Adjust the blower speed to the low setting.

    
    

    1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

       Tech Tips

       The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

    2. Maintain the engine speed at 2500 to 3000 rpm.

    3. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

       CAUTION:

       When squeezing the No. 1 and No. 2 radiator hoses:

       
       

       • Wear protective gloves.

       • Be careful as the No. 1 and No. 2 radiator hoses are hot.

       • Keep your hands away from the fans.

       Note

       
       

       • Make sure that the radiator reserve tank assembly still has some engine 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 engine coolant, the engine may overheat or be seriously damaged.

       • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

12. Stop the engine, and wait until the engine coolant cools down.

13. Add engine coolant to the full line on the radiator reserve tank assembly.

INSPECT FOR COOLANT LEAK