Generator Installation

Install the bracket with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the wire harness clamp stay with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the wire harness clamp.

Install the generator assembly to the cylinder block with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Connect the generator connector to the generator assembly.

Install the generator wire with the nut.

Torque:

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

Install the terminal cap.

Connect the 2 wire harness clamps.

Connect the magnetic clutch connector to the compressor and magnetic clutch.

Install the V-ribbed belt.

Using SST, turn the belt tensioner counterclockwise and remove the bar.

SST

09249-63010

If it is difficult to install the V-ribbed belt, perform the following procedure:

1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.
   

2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the tensioner pulley.
   

   NOTICE:

   1. Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley.
      
   2. Check that the V-ribbed belt is properly set to each pulley.
      

3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.
   

Install the radiator to the body.

Install the condenser assembly with the 4 bolts.

Torque:

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

Install the fan assembly with motor to the radiator with the 2 guides at the bottom and 3 snap fits on the top.

Connect the fan motor connector.

Install the radiator support upper with the 5 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Install the hood lock assembly to the radiator support upper with the 3 bolts.

Torque:

7.5 N*m{77 kgf*cm, 66 in.*lbf}

For LHD:
Install the hood lock control cable assembly to the radiator support upper with the clamp.

For RHD:
Install the hood lock control cable assembly to the radiator support upper with the clamp.

Connect the 2 horn connectors.

Connect the No. 1 oil cooler outlet tube to the radiator assembly.

Connect the No. 1 oil cooler inlet tube to the radiator assembly.

Connect the radiator hose outlet to the radiator assembly.

Connect the radiator hose inlet to the radiator assembly.

Connect the radiator reservoir tank hose to the radiator assembly.

Install the front bumper energy absorber to the front bumper reinforcement sub-assembly.

Connect 2 fog light connectors.

w/ TOYOTA Parking Assist-sensor System:

1. Connect the clearance sonar connector and engage the clamp.
   

Engage each claw.

Install the front bumper assembly with the 8 screws, 2 clips, 2 radiator grille protectors and bolt.

Install the pin hold clip.

HINT:

Use the same procedure for the RH side and LH side.

Connect the headlight cleaner washer hose.

Connect 2 fog light connectors.

w/ TOYOTA Parking Assist-sensor System:

1. Connect the clearance sonar connector and engage the clamp.
   

Engage each claw.

Install the front bumper assembly with the 8 screws, 2 clips, 2 radiator grille protectors and bolt.

Install the pin hold clip.

HINT:

Use the same procedure for the RH side and LH side.

Install the No. 1 air cleaner inlet with the bolt.

Torque:

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

Install the air cleaner cap sub-assembly, and connect the 3 bands.

Connect the mass air flow meter connector (^*1).

Connect the No. 2 ventilation hose (^*2).

Connect the hose band (^*3).

Connect the 3 vacuum hoses.

Install the air cleaner inlet with the clamp and 2 bolts.

Torque:

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

Close the radiator drain cock plug and 2 cylinder block drain cock plugs.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf} for cylinder block drain cock plug

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Specified capacity:

9.0 liters (9.5 US qts, 7.9 lmp. qts)

HINT:

1. 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).
   

1. Contact your TOYOTA dealer for further details.
   

Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Install the radiator cap sub-assembly and reservoir tank cap.

Start the engine, and warm it up.

HINT:

Adjust the air conditioner set temperature to MAX (HOT).

Stop the engine, and wait until the engine coolant cools down.

Add engine coolant to the FULL line on the radiator reservoir.

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

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 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 heater core, cylinder block and cylinder head.

Engage the 3 retainers to install the V-bank cover.

Install the intake duct seal with the 7 clips.