INSTALL THERMOSTAT

INSTALL WATER INLET

INSTALL NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (w/ Viscous Heater)

INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

INSTALL FAN PULLEY

INSTALL FAN SHROUD WITH FAN

INSTALL OIL COOLER TUBE (for Automatic Transmission)

INSTALL V-RIBBED BELT

INSTALL NO. 3 IDLER PULLEY (w/ Viscous Heater)

INSTALL NO. 1 IDLER PULLEY (w/ Viscous Heater)

INSTALL V-RIBBED BELT (w/ Viscous Heater)

CONNECT NO. 2 RADIATOR HOSE

CONNECT NO. 1 RADIATOR HOSE

INSTALL VANE PUMP ASSEMBLY

INSTALL RADIATOR RESERVOIR ASSEMBLY

INSTALL NO. 1 OIL RESERVOIR BRACKET

INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

INSTALL INTAKE AIR CONNECTOR

TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

INSTALL NO. 3 ENGINE ROOM WIRE

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

INSPECT FOR ENGINE COOLANT LEAK

INSTALL UPPER RADIATOR SUPPORT SEAL

INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

INSTALL FRONT FENDER APRON SEAL FRONT RH

INSTALL FRONT WHEEL RH

Install a new gasket to the thermostat.

• NOTICE:

• When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed onto the thermostat, as shown in the illustration.

Insert the thermostat into the water pump with the jiggle valve facing straight upward.

• HINT:

• The jiggle valve may be set within 30° of either side of the prescribed position.

Install the water inlet with the 4 bolts.

• Torque:
• for bolt A:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for bolt B:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

Connect the No. 2 oil cooler hose to the clamp and water pump.

Install the No. 1 idler pulley bracket with the bolt.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Install the heater assembly with the 2 bolts.

• Torque:
• 48.5 N*m{ 495 kgf*cm, 36 ft.*lbf}

Connect the 2 heater hoses.

Using pliers, grip the claws of the clips and slide the 2 clips.

Connect the connector and attach the clamp.

Connect the heater water pipe to the viscous heater with magnet clutch, and install the 4 bolts.

• Torque:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Install the shroud together with the fluid coupling fan between the radiator and engine components.

• NOTICE:

• Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the fan bracket with the 4 nuts.

• HINT:

• Tighten the nuts as much as possible by hand.

Attach the shroud claws to the radiator.

Install the shroud with the 2 bolts.

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

Tighten the 4 nuts of the fluid coupling fan.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Temporarily install the oil cooler tube to the fan shroud with the bolt labeled A. Install the bolt labeled B. Then tighten the bolt labeled A to the specified torque.

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

Connect the inlet No. 4 oil cooler hose as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Connect the inlet No. 2 and No. 3 oil cooler hoses as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Connect the inlet and outlet No. 1 oil cooler hoses as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Pass the hose through the flexible hose clamp and close the clamp shown in the illustration.

Attach a wrench to the V-ribbed belt tensioner bracket and turn the wrench clockwise.

Install the V-ribbed belt as shown in the illustration.

Check that the belt fits properly in the ribbed grooves.

• HINT:

• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

• If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.

Align the No. 3 idler pulley bracket knock pin and No. 1 idler pulley bracket knock pin hole and install the No. 3 idler pulley with the nut.

• Torque:
• 88 N*m{ 898 kgf*cm, 64 ft.*lbf}

Install the collar, No. 1 idler pulley and cover with the bolt.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Install the V-ribbed belt as shown in the illustration.

Temporarily install the lock nut, and turn the bolt clockwise.

Using a belt tension gauge, inspect the belt tension.

• Standard Belt Tension:

• Item	Condition	Specified Condition
  New belt	5 to 35°C (41 to 95°F)	550 to 800 N (56 to 82 kgf, 123.6 to 179.8 lbf)
  Used belt	5 to 35°C (41 to 95°F)	300 to 500 N (31 to 51 kgf, 67.4 to 112.4 lbf)

• HINT:

Tighten the nut.

• Torque:
• 40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Check that the belt fits properly in the ribbed grooves.

• HINT:

• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

• If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.

Apply a light coat of engine oil to a new O-ring, and install it to the vane pump.

Install the vane pump with 2 new nuts.

• Torque:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Install the radiator reservoir with the 3 bolts.

Connect the 2 hoses to the upper radiator tank and water inlet.

• HINT:

• Make sure the directions of the hose clamps are as shown in the illustration.

Install a new bracket with the 2 bolts.

• Torque:
• 4.5 N*m{ 46 kgf*cm, 40 in.*lbf}

Install the vane pump oil reservoir to the bracket.

Connect the intake air connector to the No. 1 and No. 2 air cleaner pipes.

Install the connector with the 2 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Tighten the 2 hose clamps.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

Attach the 3 wire harness clamps.

w/o Viscous Heater:

Connect the connector to the water temperature sensor.

w/ Viscous Heater:

Connect the 2 connectors to the water temperature sensor and viscous with magnet clutch heater.

Temporarily install the air cleaner hose to the intake air connector.

Connect the air cleaner cap to the air cleaner hose, and install the air cleaner cap with the 4 clamps.

Connect the mass air flow meter connector and attach the wire harness clamp to the air cleaner cap.

Attach the wire harness clamp.

Align the protrusion of the air cleaner cap and the concave portion of the air cleaner hose.

Tighten the 2 hose clamps.

• Torque:
• 2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Install the engine cover with the 2 nuts.

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

Install the No. 3 engine room wire to the main battery and sub-battery positive terminals with the 2 nuts.

• Torque:
• 7.6 N*m{ 77 kgf*cm, 67 in.*lbf}

Connect the No. 3 engine room wire with the 4 clamps.

Connect the cables to negative (-) main battery and sub-battery terminals.

Remove the engine air bleed cap.

Connect a clear hose to the engine air bleed pipe.

Using a wrench, remove the vent plug.

Fill the radiator with TOYOTA SLLC to the radiator reservoir filler neck.

• HINT:

• Pour TOYOTA SLLC until it spills out of the engine air bleed pipe.

• Standard Capacity (for Automatic Transmission):

• Item	Specified Condition
  Front heater only	14.8 liters (15.6 US qts, 13.0 Imp. qts)
  Front heater and rear heater	17.6 liters (18.6 US qts, 15.5 Imp. qts)
  Front heater with viscous heater	15.2 liters (16.1 US qts, 13.4 Imp. qts)
  Front heater and rear heater with viscous heater	18.0 liters (19.0 US qts, 15.4 Imp. qts)

• Standard capacity (for Manual Transmission):
• 15.4 liters (16.3 US qts, 13.5 Imp. qts)

• NOTICE:

• Do not substitute plain water for engine coolant.

• HINT:

• 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).

Install the vent plug.

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

• NOTICE:

• Do not tighten the plug to 5.0 N*m (51 kgf*cm, 44 in.*lbf) or more, as the plug will be damaged.

Disconnect the clear hose from the engine air bleed pipe.

Install the engine air bleed cap when coolant comes out.

Install the radiator reservoir cap.

Start the engine.

• NOTICE:

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

Maintain an engine speed of 3000 rpm for approximately 10 minutes so that the thermostat opens and air bleeding is performed.

• CAUTION:

• NOTICE:

• HINT:

• The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

Stop the engine, and wait until the engine 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.

Check that the coolant level is between the FULL and LOW lines.

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

Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 17.8 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 cylinder head.

Install the upper radiator support seal with the 7 clips.

Install the No. 1 engine under cover with the 10 bolts.

• Torque:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Install the front fender splash shield RH with the clip, and then install the 3 bolts and 2 screws.

Install the front fender splash shield LH with the clip, and then install the 3 bolts and screw.

Install the front fender apron seal front RH with the 3 clips.