THERMOSTAT (w/o EGR Cooler) INSTALLATION

INSTALL THERMOSTAT
1. Install a new gasket to the thermostat.
  
  Tech Tips
  
  When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.
2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.
  
  Tech Tips
  
  The jiggle valve may be set within 30°of either side of the prescribed position.
INSTALL WATER INLET
1. Install the water inlet with the 3 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
CONNECT RADIATOR HOSE OUTLET
1. Connect the radiator hose outlet to the water inlet.
CONNECT NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)
1. Connect the No. 1 automatic transmission oil cooler tube clamp to the water inlet with the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL COMPRESSOR INLET ELBOW (w/ Intercooler)
1. Install the No. 12 water by-pass hose to the compressor inlet elbow.
2. Install the No. 2 water by-pass hose and No. 7 water by-pass hose to the compressor inlet elbow.
3. Install a new gasket and the compressor inlet elbow with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
4. Connect the No. 13 water by-pass hose to the No. 2 water by-pass pipe sub-assembly.
5. Connect the No. 2 water by-pass hose to the No. 1 turbo water pipe sub-assembly.
6. Connect the No. 1 turbo water hose to the cylinder block.
7. Connect the 2 connectors and attach the wire harness clamp.
INSTALL VENTILATION PIPE (w/ Intercooler)
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. for Variable Nozzle Vane Turbocharger:
  
  Connect the No. 12 water by-pass hose and No. 13 water by-pass hose.
INSTALL AIR CLEANER ASSEMBLY
1. w/o Mass Air Flow Meter:
  1. Connect the air cleaner hose.
  2. Install the air cleaner with the 2 bolts.
    
    Torque:
    
    14 N*m { 143 kgf*cm, 10 ft.*lbf }
  3. Tighten the clamp.
  4. Install the clamp and connect the intake air temperature sensor connector.
  5. Connect the ventilation hose.
  6. Slide the clamp to the connection of the hose.
2. w/ Mass Air Flow Meter:
  1. Connect the air cleaner hose.
  2. Install the air cleaner with the 2 bolts.
    
    Torque:
    
    14 N*m { 143 kgf*cm, 10 ft.*lbf }
  3. w/o Intercooler:
    
    Connect the ventilation hose.
  4. Connect the connector to the mass air flow meter.
  5. Tighten the hose clamp.
INSTALL VENTILATION HOSE HEAT INSULATOR (w/o Intercooler)
1. Install the insulator with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

Standard Capacity

Item	Specified Condition
for Automatic Transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)
for Manual Transmission	9.8 liters (10.4 US qts, 8.6 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 consists of a combination of low phosphates and organic acids).

Please contact your TOYOTA dealer for further details.

Note

Never use water as a substitute for engine coolant.

Press the radiator hose inlet and radiator hose outlet several times by hand, and then check the level of the coolant.

If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
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.
2. Maintain the engine speed at 2500 to 3000 rpm.
3. Press the radiator hose inlet and radiator hose outlet several times by hand to bleed air.
  CAUTION:
  
  When pressing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
4. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
After the coolant cools down, check that the coolant level is at the F line.

If the coolant level is below the F line, add TOYOTA SLLC to the F line.

INSPECT FOR COOLANT LEAK
Note

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm²,17.1 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 cylinder block and head.
INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

Click here
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.