Thermostat Installation

Install a new gasket to the thermostat.

Install the thermostat with the jiggle valve facing up.

NOTICE:

The jiggle valve must be set within 10° of the position shown in the illustration. Failure to do so may result in engine overheating.

Install the water inlet with the 3 bolts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Connect the radiator outlet hose to the water inlet and secure them with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

Install the wire harness clamp to the water inlet.

Connect the wire harness clamp.

Install the air pipe sub-assembly with the bolt.

Torque:

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

Connect the intake air temperature sensor connector.

Tighten the 3 hose bands.

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}

Connect the 2 diesel throttle body connectors.

Install the No. 1 water outlet pipe with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf}

Connect the 2 water hoses with the 2 bands.

Connect the manifold absolute pressure sensor connector and vacuum hose.

Install the intake manifold insulator.

HINT:

Insert the intake manifold insulator between the EGR valve and common rail to make contact with the intake manifold.

Install 2 new gaskets.

Temporarily install No. 2 EGR pipe with the bolt and nut.

Temporarily install the bolt and tighten the 2 bolts.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Temporarily install the nut and tighten the 2 nuts.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Install the wiring harness clamp bracket with the 2 bolts.

Torque:

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

Connect the oil pressure switch assembly connector (^*1).

Connect the EGR valve connector (^*2).

Connect the 6 wire harness clamps (^*3).

Connect the wire harness clamp.

Tighten all the plugs.

Torque:

for cylinder block drain cock plug:

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

Add engine coolant.

Specified capacity:

8.9 liters (9.4 US qts, 7.8 lmp. qts)

HINT:

1. The coolant reserve tanks of 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 that 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 until it reaches the FULL line.

Squeeze 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.

Bleed air from the cooling system.

NOTICE:

Before starting the engine, turn the A/C switch off.

1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
   

   HINT:

   The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

   NOTICE:

   When squeezing the radiator hose:

   1. Wear protective gloves.
      
   1. Be careful as the radiator hoses are hot.
      
   1. Keep your hands away from the radiator fan.
      

2. Maintain the engine speed at 2,000 to 2,500 rpm.
   

3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
   

   NOTICE:

   When squeezing the radiator hoses:

   1. Wear protective gloves.
      
   1. Be careful as the radiator hoses are hot.
      
   1. Keep your hands away from the radiator fan.
      

Stop the engine and wait until the engine coolant cools down to ambient temperature.

CAUTION:

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

Check the coolant level in the reserve tank.
If the coolant level is low, add coolant to the reserve tank FULL line.

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 177 kPa (1.8 kgf/cm, 26 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.

Install the side cover with the 4 clips.

Install the inlet air cleaner with the bolt and clip.

Torque:

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

Install the intake duct seal with the 11 clips.

Install the No. 1 engine cover.