INTERCOOLER INSTALLATION


  1. INSTALL INTERCOOLER ASSEMBLY


    1. Install the intercooler with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the No. 1 vacuum transmitting hose to the intercooler.

  2. INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the lower radiator support RH with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the clamp to the vacuum transmitting pipe, and then install the lower radiator support LH with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  3. INSTALL NO. 2 AIR TUBE


    1. A01INTX

      Install the No. 2 air tube with the bolt.

      Note

      Before installation, remove any oil residue from the inside of the pipe and hose.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    2. A01INBYE01

      Tighten the hose clamp.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips

      Position the tube end so that the distance from the intercooler pipe is 0 to 2 mm (0 to 0.0787 in.).

    3. Connect the air temperature sensor connector.

  4. INSTALL RADIATOR ASSEMBLY


    1. Install the 2 radiator lower support cushions.

    2. A01ITC1

      Insert the radiator with intercooler while holding it at an angle to install it as shown in the illustration.

      Note

      Do not apply any excessive force to the cooler pipe when installing the radiator assembly.

    3. A01IP4Y

      for Automatic Transaxle:

      Connect the 2 oil cooler hoses and attach the 2 clips.

    4. A01IUHU

      Connect the No. 2 vacuum transmitting hose.

  5. INSTALL CONDENSER ASSEMBLY WITH RECEIVER


    1. A01IPIA

      Install the condenser assembly with receiver as shown in the illustration.

      Tech Tips

      If the condenser is replaced with a new one, add compressor oil to the new condenser.

      Capacity
      40 cc (1.4 fl.oz.)
      Compressor oil
      ND-8 or equivalent

  6. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A01IQCM

      Install the radiator support with the 4 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  7. INSTALL HOOD LOCK ASSEMBLY


    1. A01INS6E01
      Text in Illustration
      *1 MP grease

      Apply MP grease to the sliding areas of the lock.

    2. for LHD:


      1. A01IO2N

        Connect the hood lock control cable.

      2. A01IS1Z

        Install the hood lock with the 3 bolts.

        Torque:
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. for RHD:


      1. A01IQR4

        Connect the hood lock control cable.

      2. A01ITHB

        Connect the connector.

      3. Install the hood lock with the 3 bolts.

        Torque:
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  8. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01IN1Q

      Install the 2 upper radiator supports with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the 2 radiator support cushions.

  9. INSTALL UPPER RADIATOR SUPPORT (for Manual Transaxle)


    1. A01IT2T

      Install the 2 upper radiator supports with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  10. INSTALL UPPER RADIATOR SUPPORT (for Automatic Transaxle)


    1. A01IRTC

      Install the 2 upper radiator supports with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 in.*lbf }

  11. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.

    4. A01IQ6T

      Connect the air conditioning tube and accessory assembly to the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  12. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the pipe and connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

    4. A01IUGE

      Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  13. INSTALL NO. 3 AIR HOSE

    Note

    Before installation, remove any oil residue from the inside of the throttle body and tube.


    1. A01IO15E01

      Align the paint mark of the No. 3 air hose with the embossed mark of the throttle body.

    2. Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.

    3. A01IQ7SE01

      Tighten the clamp of the No. 3 air hose on the diesel throttle body side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

    4. A01IP6QE01

      Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

  14. INSTALL INTERCOOLER AIR HOSE (for Manual Transaxle)

    Note


    • Check that the retainer is closed when the connector is inserted.

    • If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.

    • If replacing the hose, apply fresh oil to the O-ring.

    • Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.

    • Do not use a quick connector that has been dropped.


    1. A01ITOHE01
      Text in Illustration
      *1 Retainer

      Install the intercooler air hose to the intercooler and No. 1 air tube and push in the retainer.

    2. Tighten the hose clamp.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  15. INSTALL INTERCOOLER AIR HOSE (for Automatic Transaxle)

    Note

    Before installation, remove any oil residue from the inside of the tube.


    1. A01IU8OE02

      Install the intercooler air hose to the No. 1 air tube and intercooler and tighten the 2 hose clamps.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
    2. A01IR3Y

      Install the wire harness clamp with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    3. Attach the clamp.

  16. CONNECT NO. 2 RADIATOR HOSE


    1. A01IRFME01

      Install the No. 2 radiator hose.

      Tech Tips

      Position the clips as illustrated.

  17. INSTALL NO. 1 RADIATOR HOSE


    1. A01IT0NE01

      Connect the No. 1 radiator hose.

      Tech Tips

      Position clips A and B as Illustrated.

  18. INSTALL INJECTOR DRIVER


    1. A01IO2Q

      Install the injector driver bracket with the 4 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    2. A01IOBA

      Install the injector driver with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    3. A01IPA6

      Attach the clamp and connect the 4 connectors.

  19. CONNECT NO. 1 WATER HOSE CLAMP BRACKET


    1. A01IPG1

      Connect the No. 1 water hose clamp bracket to the radiator support with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Attach the 2 hose clamps to the No. 2 by-pass water hose, and then connect the No. 1 radiator hose to the No. 1 water hose clamp bracket.

  20. INSTALL NO. 3 WATER BY-PASS HOSE


    1. A01IRP9

      Connect the 3 connectors and attach the clamp.

    2. A01IQOI

      Install the No. 3 water by-pass hose and attach the clamp.

  21. INSTALL NO. 2 RADIATOR SIDE AIR SEAL


    1. A01ITUV

      Install the No. 2 radiator side air seal.

  22. INSTALL NO. 1 RADIATOR SIDE AIR SEAL


    1. A01IRKQ

      Install the No. 1 radiator side air seal.

  23. INSTALL LOW PITCHED HORN ASSEMBLY


    1. Install the low pitched horn assembly with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      A01IP2CE01

    2. Connect the horn connector.

  24. CONNECT AMBIENT TEMPERATURE SENSOR

    A01IPBA

    1. Attach the clamp to install the sensor.

    2. Connect the connector.

  25. INSTALL BATTERY CARRIER


    1. A01ISD1

      Install the battery carrier with the 4 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

    2. Attach the 2 clamps to connect the wire harness.

  26. INSTALL BATTERY TRAY

  27. INSTALL BATTERY

  28. INSTALL BATTERY INSULATOR

  29. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A01IP71

      Attach the hook of the battery clamp to the battery carrier.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Adjust the battery clamp position.

    4. Tighten the nut and bolt.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  30. INSTALL OIL COOLER ASSEMBLY (for Automatic Transaxle)


    1. A01IT9I

      Install the oil cooler with the 3 bolts and nut.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Connect the 2 oil cooler hoses and attach the 2 clips.

  31. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  33. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      for Type A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for Type B
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    3. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

      Standard Capacity
      Item Specified Condition
      w/o Power Heater 7.4 liters (7.8 US qts, 6.5 Imp. qts)
      w/ Power Heater 7.8 liters (8.2 US qts, 6.9 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.

    4. A01IQ5WE01
      Text in Illustration
      *1 Air Release Plug

      Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.

    5. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    6. Install the cap and air release plug, and warm up the engine sufficiently.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.

      Note


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

      • Adjust the air conditioning temperature setting to MAX (HOT).

      • Adjust the air conditioning blower setting to Lo.


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

        Tech Tips

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hoses:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern at least 8 times).

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hoses:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. A01IQM4

      After the engine has cooled down, check that the coolant level is between FULL and LOW.

      If the coolant level is low, add coolant until the coolant level reaches the reservoir tank FULL line.

  34. ADJUST AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

    Click here

  35. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      440 +/-30 g (15.5 +/-1.1 oz)
      A01IS7RE26

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 100 g (3.53 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  36. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  37. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation observing the following instructions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A01IPCYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

  38. INSPECT FOR COOLANT LEAK


    1. Remove the radiator reservoir cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01IU3X

      Fill the radiator with coolant, and then attach a radiator cap tester.

    3. Warm up the engine.

    4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage.

      If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the radiator reservoir cap.

  39. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.

  40. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A01IPJ8

      Insert the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.

    2. Install the 4 bolts.

    3. A01IOQE

      Install the 2 clips.

  41. INSTALL NO. 1 ENGINE UNDER COVER


    1. A01IRQL

      Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  42. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here