Thermostat Installation

Install a new gasket to the thermostat.

Install the thermostat with the jiggle valve upward.

HINT:

The jiggle valve may be set within 10° to either side of the prescribed position.

Install a new gasket and the water inlet to the timing chain cover sub-assembly with the bolt and 2 nuts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Connect the No. 2 radiator hose to the water inlet, and slide the hose clamp to secure the hose.

Connect the vane pump assembly with the 2 bolts.

Torque:

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

Connect the 2 connectors.

Install the pressure feed tube with the bolt.

Torque:

28 N*m{285 kgf*cm, 21 ft.*lbf}

Install the fan and generator V belt to all the pulleys except the tensioner pulley.

Use the hexagonal part indicated by the arrow in the illustration to move the tensioner pulley downward and install the fan and generator V belt to the tensioner pulley.

NOTICE:

1. The backside of the fan and generator V belt should face the tensioner pulley.
   
2. Check that the fan and generator V belt is properly set on each pulley.
   

Tighten the cylinder block drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Disconnect the 2 vinyl hoses.

Add engine coolant.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/o Rear Heater	8.1 liters (8.6 US qts, 7.1 Imp. qts)
	w/ Rear Heater	9.9 liters (10.5 US qts, 8.7 Imp. qts)
for Manual Transmission	w/o Rear Heater	8.3 liters (8.8 US qts, 7.3 Imp. qts)
	w/ Rear Heater	10.1 liters (10.7 US qts, 8.9 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

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).
   
2. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

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

Install the reservoir cap.

Install the radiator cap sub-assembly.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap sub-assembly and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap sub-assembly.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. 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 F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.
   
2. 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, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap sub-assembly and check the coolant level.*7

CAUTION:

Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly to 123 kPa (1.3 kgf/cm², 18 psi), and then check that the pressure does not drop.
If the pressure drops, check the hose, radiator assembly and engine water pump assembly for leakage. If no external leakage is found, check the heater core, cylinder block and cylinder head.

Hook the No. 1 engine under cover sub-assembly to the vehicle body as shown in the illustration.

Install the 4 bolts.

Torque:

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

Install the front bumper cover lower with the 5 bolts and clip.

Torque:

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

Install the upper radiator support seal with the 13 clips.