RADIATOR INSTALLATION

INSTALL INTERCOOLER ASSEMBLY

1. Install the intercooler assembly with the 4 bolts.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

INSTALL LOWER RADIATOR SUPPORT SUB-ASSEMBLY

1. Install the lower radiator support sub-assembly RH with the 2 bolts.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

2. Install the lower radiator support sub-assembly LH with the 2 bolts.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

INSTALL CONDENSER ASSEMBLY WITH RECEIVER (w/ Air Conditioning System)

INSTALL HOOD LOCK ASSEMBLY

CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning System)

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. 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 }

CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

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. 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 }

INSTALL LOW PITCHED HORN ASSEMBLY

1. Connect the horn connector to install the low pitched horn assembly.

2. Install the bolt.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

CONNECT AMBIENT TEMPERATURE SENSOR

1. Attach the clamp to install the cooler thermistor (ambient temperature sensor).

2. Connect the connector.

INSTALL BATTERY CARRIER

1. 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 engine wire.

INSTALL BATTERY CLAMP SUB-ASSEMBLY

1. Attach the hook of the battery clamp sub-assembly to the battery carrier.

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

3. Adjust the battery clamp sub-assembly 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 }

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. 

   Text in Illustration

   *1	Air Release Valve
   *a	Radiator Reservoir Assembly Filler Neck
   *b	Pour Limit Line

   Remove the air release valve.

3. Add engine coolant to the pour limit line of the radiator reservoir assembly.

   Standard Capacity
   Item Specified Condition w/o Combustion Type Power Heater 7.0 liters (7.4 US qts, 6.2 Imp. qts) w/ Combustion Type Power Heater 7.3 liters (7.7 US qts, 6.4 Imp. qts)

   Note

   Never use water as a substitute for engine coolant.

   Tech Tips

   Toyota recommends the use of approved "Toyota Premium Long Life Coolant for 1WW/2WW engines" or equivalent.

4. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand, and then check the level of the engine coolant.

   If the coolant level is low, add engine coolant.

5. Install the air release valve.

6. Add engine coolant to the filler neck of the radiator reservoir assembly.

7. Install the reservoir cap.

8. Start the engine, and warm it up until the cooling fan operates.

   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.

9. Maintain the engine speed at 2000 to 2500 rpm and warm up the engine until the cooling fan operates.

   Note

   
   

   • Make sure that the radiator reservoir assembly still has some engine coolant in it.

   • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

   • If there is not enough engine coolant, the engine may burn out or overheat.

   • Immediately after starting the engine, if the radiator reservoir assembly does not have any coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the coolant is filled to the pour limit line.

   • Until the coolant level has stabilized, run the engine at 2000 rpm.

10. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand to bleed air.

    CAUTION:

    
    

    • Wear protective gloves.

    • Be careful as the radiator hoses are hot.

    • Keep your hands away from the cooling fan.

11. Stop the engine and wait until the coolant cools down to ambient temperature.

12. Check that the coolant level is between the FULL and LOW line.

    If the coolant level is below the LOW line, repeat all of the procedures above.

    If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

CHARGE REFRIGERANT (w/ Air Conditioning System)

WARM UP ENGINE (w/ Air Conditioning System)

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.

INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

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. 

   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.

INSPECT FOR COOLANT LEAK

1. Remove the reservoir cap.

   CAUTION:

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

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

3. Warm up the engine.

4. Pump the radiator cap tester to 143 kPa (1.5 kgf/cm², 20.7 psi), and then check that the pressure does not drop.

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

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

5. Reinstall the reservoir cap.

INSTALL NO. 1 ENGINE COVER

1. 

   Text in Illustration

   *a	Installation Points

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

   Tech Tips

   When attaching the clips, press the protrusions on the top of the No. 1 engine cover at the clip installation points.