THERMOSTAT INSTALLATION

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.

   54 N*m

   550 kgf*cm

   40 ft.*lbf

INSTALL V-RIBBED BELT

1. 

   Install the V-ribbed belt.

   Table 2. Text in Illustration

   *1	Water Pump
   *2	Idler
   *3	Generator
   *4	Crankshaft
   *5	V-ribbed belt Tensioner
   *6	A/C Compressor

2. 

   Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench.

3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the 2 cylinder block drain cock plugs.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Remove the radiator cap.

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 coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

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

   Standard capacity
   9.5 liters (10.0 US qts, 8.3 lmp. qts)

   Tip:
   

   • 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.

7. Tighten the air drain plug.

8. 

   Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

   Table 3. Text in Illustration

   *1

   FULL Line

9. Install the radiator cap.

10. 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.

11. 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.

       Tip:

       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 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.

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

13. Add engine coolant to the FULL line on the radiator reservoir.

INSPECT FOR COOLANT LEAK

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 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

1. Engage the guide.

2. Install the engine room side cover with the 4 clips.

INSTALL ENGINE ROOM SIDE COVER LH

1. Engage the guide.

2. Install the engine room side cover LH with the 4 clips.

INSTALL FRONT FENDER APRON SEAL RH

1. 

   Install the front fender apron seal RH with the 2 bolts and clip.