THERMOSTAT INSTALLATION

INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
1. Install a new gasket on the water inlet with thermostat sub-assembly.
2. Install the water inlet with thermostat sub-assembly with the 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY
1. Connect the No. 2 radiator hose sub-assembly to the water inlet with thermostat sub-assembly and slide the clip to secure the hose.
INSTALL RADIATOR HOSE SUB-ASSEMBLY
1. Install the radiator hose sub-assembly to the water outlet sub-assembly and radiator assembly, and slide the 2 clamps to secure the hoses.
CONNECT AIR CONDITIONING HARNESS
1. Text in Illustration
  
  *a Green-colored Lock
  
  Connect the connector and slide the green-colored lock as shown in the illustration to engage it securely.
  
  CAUTION:
  
  Make sure to wear insulating gloves.
  
  Note
  
  Make sure that the connector is connected securely.
2. Connect the 2 wire harness clamps.
INSTALL SERVICE PLUG GRIP

Click here

Text in Illustration
*a	Green-colored Lock

ADD ENGINE COOLANT

CAUTION:

Do not remove the water filler cap sub-assembly or reservoir tank cap while the engine and radiator assembly are still hot. Pressurized hot engine coolant and steam may be released and cause serious burns.

Tech Tips

Before starting the engine to warm up the engine, turn the A/C switch off.

Tighten the radiator drain cock sub-assembly by hand.
Remove the vinyl tube from the radiator drain cock.
Install the No. 4 center engine under cover with the 3 screws.

Text in Illustration
*a	[AR] B line

Add engine coolant to the [AR] B line of the radiator reservoir tank assembly. [*1]

Standard Capacity

Item	Specified Condition
Engine Coolant	8.4 liters (8.9 US qts, 7.4 Imp. qts)

Note

Do not reverse the position of the reservoir tank cap and water filler cap sub-assembly when installing them. Doing so may damage the parts.
Do not substitute plain water for engine coolant.
Apply a light coat of engine coolant to the O-ring of the water filler cap sub-assembly when installing the water filler cap sub-assembly.

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).

Install the reservoir tank cap.
Add engine coolant to the radiator pipe filler hole.
Tech Tips
- Install the water filler cap sub-assembly.
- Squeeze radiator hose sub-assembly and No. 2 radiator hose sub-assembly several times by hand, and then check the level of the engine coolant.
  
  If the engine coolant level is low, add engine coolant.
Put the engine in inspection mode (maintenance mode). [*2] Click here
Bleed air from the cooling system. [*3]
CAUTION:
- 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 water inlet with thermostat sub-assembly opens. While the water inlet with thermostat sub-assembly is open, circulate the engine coolant for several minutes.
  CAUTION:
  
  When squeezing the radiator hose sub-assembly and No. 2 radiator hose sub-assembly :
  - Wear protective gloves.
  - Be careful as the radiator hose sub-assembly and No. 2 radiator hose sub-assembly are hot.
  - Keep your hands away from the fan and No. 2 fan.
  Note
  - Make sure that the radiator reservoir 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 reservoir tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant cools down, and 3) add engine coolant until the radiator reservoir tank assembly is filled to the full line.
  Tech Tips
  
  The water inlet with thermostat sub-assembly open timing can be confirmed by squeezing the radiator hose sub-assembly by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose sub-assembly.
2. Squeeze the radiator hose sub-assembly and No. 2 radiator hose sub-assembly several times by hand to bleed air.
3. Stop the engine, and wait until the engine coolant cools down. [*4]
4. Check that the engine coolant level is between the full and low. [*5]
  Tech Tips
  - If the engine coolant level is below the low, repeat steps from [*1] to [*5].
  - If the engine coolant level is above the full, drain engine coolant so that the engine coolant level is between the full and low.

INSPECT FOR COOLANT LEAK
CAUTION:

Do not remove the water filler cap sub-assembly or reservoir tank cap while the engine and radiator assembly 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 reservoir tank cap.
2. Fill the radiator reservoir tank assembly with coolant and attach a radiator cap tester.
3. Put the engine in inspection mode (maintenance mode). Click here
4. Warm up the engine.
5. Using a radiator cap tester, increase the pressure inside the radiator assembly to 137 kPa (1.4 kgf/cm², 20 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block sub-assembly and cylinder head sub-assembly.
6. Remove the radiator cap tester.
7. Install the reservoir tank cap.