INSTALL GENERATOR ASSEMBLY

INSTALL NO. 1 AIR TUBE ASSEMBLY

INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

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

INSTALL NO. 3 AIR TUBE

INSTALL NO. 1 AIR HOSE

INSTALL INTAKE AIR CONNECTOR

TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

CONNECT WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)

INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

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 CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

INSPECT FOR COOLANT LEAK

INSTALL FRONT FENDER APRON SEAL REAR RH

INSTALL FRONT FENDER APRON SEAL FRONT RH

INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Temporarily install the generator with the 2 stud bolts.

Using an E7 "TORX" socket wrench, tighten the 2 stud bolts.

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

Install the 2 nuts and 3 bolts in the order shown in the illustration.

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

Install the the No. 1 intake air connector pipe to the No. 1 inlet compressor elbow.

Install the No. 1 intake air connector bracket with the 2 bolts.

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

Install the bolt to the No. 1 intake air connector pipe. Then tighten the hose clamp.

• Torque:
• for bolt:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for hose clamp:
• 6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Connect the wire harness bracket to the belt tensioner with the bolt.

• Torque:
• 13 N*m{ 133 kgf*cm, 10 ft.*lbf}

130 A Type and 150 A Type:

Connect the generator wire with the nut.

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

180 A Type:

Connect the generator wire with the nut.

• Torque:
• 12 N*m{ 122 kgf*cm, 9 ft.*lbf}

Install the terminal cap.

Connect the 6 wire harness clamps.

Connect the 4 connectors.

Apply a light coat of washer fluid to a new O-ring and install it to the No. 1 air tube.

Install the No. 1 air tube with the bolt.

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

Connect the No. 1 air cleaner pipe to the No. 1 intake air connector pipe.

Install the pipe with the bolt.

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

Tighten the hose clamp.

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

Connect the 4 water hose ends, and install the water pipe with the 4 bolts.

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

Install the No. 3 air tube with the bolt.

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

Tighten the hose clamp.

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

• HINT:

• Make sure the direction of the hose clamp is as shown in the illustration.

Install the wire harness bracket with the bolt.

Install the ground wire with the nut, and attach the wire harness clamp.

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

Connect the No. 1 air hose with the hose clamp.

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

• HINT:

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}

Apply a light coat of engine oil to a new O-ring.

Install the O-ring to the No. 2 engine oil level dipstick guide.

Install the No. 2 engine oil level dipstick guide with the 2 bolts.

• Torque:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Connect the ventilation hose to the cylinder head cover RH.

Connect the wire harness clamp to the No. 2 engine oil level dipstick guide bracket.

Connect the 2 water hoses.

Install a new gasket to the air tube LH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 2 cool air inlet with the 3 nuts and bolt.

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

Connect the No. 2 air hose to the No. 2 cool air inlet.

Tighten the No. 2 air hose clamp.

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

• HINT:

Install a new gasket to the air tube RH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 1 cool air inlet with the 3 nuts and bolt.

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

Connect the vacuum hose, intake air temperature sensor connector and turbo pressure sensor connector.

Connect the No. 1 air hose to the No. 1 cool air inlet.

Tighten the No. 1 air hose clamp.

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

• HINT:

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.

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 front fender apron seal rear RH with the 4 clips.

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

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

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

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.