THERMOSTAT INSTALLATION

INSTALL THERMOSTAT
1. Install a new gasket to the thermostat.
2. Text in Illustration
  
  *1 Jiggle Valve
  
  Install the thermostat with the jiggle valve facing upward.
  
  Tech Tips
  
  The jiggle valve may be set to within 10° on either side of the prescribed position.
INSTALL WATER INLET
1. Install the water inlet with the 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
CONNECT NO. 2 RADIATOR HOSE
1. Connect the No. 2 radiator hose.
INSTALL GENERATOR ASSEMBLY

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ADD ENGINE COOLANT
1. Tighten the radiator drain cock by hand.
2. Remove the radiator cap.
3. Loosen the air drain valve.
4. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain valve hole. Then tighten the air drain valve.
5. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).
  
  Standard Capacity
  
  6.7 liters (7.1 US qts, 5.9 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.
6. Text in Illustration
  
  *a Full Line
  
  Slowly pour coolant into the radiator reserve tank until it reaches the full line.
7. Install the radiator cap.
8. 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.
9. Bleed air from the cooling system.
  1. 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.
  2. Maintain the engine speed at 2500 to 3000 rpm.
  3. 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 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.
    - If the radiator reserve tank 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 radiator reserve tank is filled to the full line.
10. Stop the engine and wait until the engine coolant cools down.
11. Add engine coolant to the full line on the radiator reserve tank.
INSPECT FOR COOLANT LEAK
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. Warm up the engine.
4. 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 and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
5. Remove the radiator cap tester.
6. Install the radiator cap.
INSTALL NO. 1 ENGINE UNDER COVER