ENGINE OIL COOLER INSTALLATION

INSTALL OIL COOLER ASSEMBLY
1. Install 2 new gaskets and the oil cooler with the 4 nuts to the filter bracket.
  
  Torque:
  
  15.5 N*m { 158 kgf*cm, 11 ft.*lbf }
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
1. Install a new gasket and oil filter bracket with the 10 bolts and 2 nuts.
  
  Torque:
  
  29.5 N*m { 301 kgf*cm, 22 ft.*lbf }
INSTALL OIL FILTER SUB-ASSEMBLY
1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Install the oil filter, and tighten it by hand until the gasket contacts the installation surface.
4. Using SST, tighten it by an additional 3/4 turn to seat the filter.
  
  SST
  
  09228-44011
INSTALL EXHAUST MANIFOLD
1. Install a new gasket to the cylinder head.
  
  Tech Tips
  
  Be sure to install a new gasket in the correct direction as shown in the illustration.
2. Install the exhaust manifold with the 6 bolts and 2 new nuts. Uniformly tighten the bolts and nuts in several steps.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
INSTALL FRONT EXHAUST PIPE
1. Install the front exhaust pipe Click here.
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 3 bolts.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf, for bolt A }
  
  19 N*m { 195 kgf*cm, 14 ft.*lbf, for bolt B }
INSTALL VACUUM PUMP OIL INLET HOSE
1. Connect the vacuum pump oil inlet hose with 2 new gaskets and the union bolt.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
  
  Tech Tips
  
  When tightening the inlet hose, hang the stopper-bar of the inlet hose on the filter bracket to prevent the inlet hose from rotating.
INSTALL GENERATOR WITH VACUUM PUMP ASSEMBLY
1. Install the generator with the bolt.
  
  Torque:
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
2. Connect the vacuum oil outlet hose.
3. Install 2 new gaskets and the vacuum pump hose with the union bolt.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
4. Install the vacuum pump oil inlet hose with 2 new gaskets and the union bolt.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
5. Attach the vacuum pump oil inlet hose to the cord clip.
6. Install the generator wire with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 7 ft.*lbf }
7. Attach the terminal cap.
8. Connect the generator connector.
INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the compressor mounting bracket with the 4 bolts.
2. Using several steps, uniformly install and tighten the 4 bolts.
  
  Torque:
  
  85 N*m { 870 kgf*cm, 63 ft.*lbf }
3. Temporarily install the spacer with the bolt.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Install the compressor with the 4 bolts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning System)
1. Install the V belt.
2. Tightening the bolt C, adjust the deflection of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the deflection of the V belt Click here.
INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning system)
1. Install the V belt.
2. Using a bar, adjust the tension of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the deflection of the V belt Click here.
INSTALL COOLER COMPRESSOR V BELT (w/ Air Conditioning System)
1. Install the V belt.
2. Tightening the bolt B, adjust the tension of the V belt.
3. Tighten nut A.
  
  Torque:
  
  39 N*m { 400 kgf*cm, 29 ft.*lbf }
4. Check the tension of the V belt Click here.
INSTALL VANE PUMP V BELT
1. Install the V belt.
2. Using a bar, adjust the tension of the V-ribbed belt.
3. Tighten the bolt A and nut B.
  
  Torque:
  
  Bolt (A)
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Nut (B)
  
  64 N*m { 635 kgf*cm, 47 ft.*lbf }
4. Check the tension of the V belt Click here.
INSTALL INTAKE PIPE ASSEMBLY
1. Install the intake pipe with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Tighten the intake pipe clamp.
INSTALL AIR CLEANER SUB-ASSEMBLY
1. Install the cleaner with the 2 bolts.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
2. Connect the connector to the IAT meter.
3. Connect the hose clamp.

ADD ENGINE OIL

Add fresh engine oil.

Standard capacity

Item	Specified Condition
Drain and refill with oil filter change	7.2 liters (7.6 US qts, 6.3 Imp. qts)
Drain and refill without oil filter change	6.7 liters (7.1 US qts, 5.9 Imp. qts)
Dry fill	8.4 liters (8.9 US qts, 7.4 Imp. qts)

Reinstall the oil filler cap.

ADD ENGINE COOLANT
1. Tighten the radiator drain cock plug by hand.
2. Tighten the cylinder block drain cock plug.
  
  Torque:
  
  57 N*m { 581 kgf*cm, 42 ft.*lbf }
3. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's FULL line.
  
  Standard capacity
  
  9.4 liters (9.9 US qts, 8.3 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.
4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
  
  If the coolant level drops below the FULL line, add TOYOTA SLLC to the FULL line.
5. Install the radiator reservoir cap.
6. Using a wrench, install the vent plug.
  
  Torque:
  
  2.0 N*m { 20 kgf*cm, 18 in.*lbf }
7. 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 2,500 to 3,000 rpm.
  3. Press the inlet and outlet radiator hoses 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.
8. After the coolant cools down, check that the coolant level is at the FULL line.
  
  If the coolant level is below the low line, add TOYOTA SLLC to the FULL line.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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.
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS
1. Check for engine coolant leaks Click here.
INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)
1. Install the under cover with the 2 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)
1. Install the under cover with the 4 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }