Thermostat Installation

Install a new gasket to the thermostat.

Install the thermostat with the jiggle valve facing upward.

NOTICE:

The jiggle valve can be set to within 10° of either side of the indicated position.

Install the water inlet with the 2 nuts.

Torque:

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

Install the No. 2 idler pulley cover plate and No. 2 idler pulley with the bolt.

Torque:

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

Install the front No. 1 engine mounting bracket LH with the 6 bolts.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

NOTICE:

1. Install the water inlet housing and mounting bracket within 15 minutes after installing the chain cover.
   
2. Do not start the engine for at least 2 hours after installation.
   

Install the engine mounting insulator RH with the 2 nuts and 5 bolts.

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf} for bolt

95 N*m{969 kgf*cm, 70 ft.*lbf} for nut A

52 N*m{530 kgf*cm, 38 ft.*lbf} for nut B

Rotate the tensioner pulley counterclockwise, and then install the V-ribbed belt.

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

1. Put the V-ribbed belt on everything 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.
      

Connect the radiator reservoir tank with the 2 bolts.

Torque:

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

Install the cover with the 9 clips.

Attach the 3 clips to install the engine cover.

Tighten the radiator drain cock plug by hand.

Tighten the 2 cylinder block drain cock plugs.

Torque:

13 N*m{130 kgf*cm, 10 ft.*lbf}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Continue adding TOYOTA SLLC until it is filled to the B line at the base of the reservoir's filler neck.

Standard capacity:

9.3 liters (9.8 US qts, 8.2 Imp. qts)

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).

NOTICE:

Never use water as a substitute for engine coolant.

Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Start the engine and warm it up until the cooling fan operates. While the cooling fan operates, circulate the coolant for several minutes.

1. Set the air conditioning as follows while warming up the engine.
   

   Item	Specified Condition
   Manual Air Conditioning System	Fan speed: Any setting except OFF
   	Temperature: Toward WARM Air conditioning switch: OFF
   Automatic Air Conditioning System	Temperature: Toward MAX Air conditioning switch: OFF

2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.
   

   NOTICE:

   1. Make sure that some coolant remains in the radiator reservoir.
      
   2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
      
   3. If there is not enough coolant, the engine may burn out or overheat.
      
   4. 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 B line.
      
   5. Run the engine at 2,000 rpm until the coolant level has stabilized.
      

Squeeze the No. 1 and No. 2 radiator hoses several times to bleed air.

CAUTION:

When squeezing the radiator hoses:

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

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

Check that the coolant level is between the FULL and LOW lines.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.

Remove the radiator reservoir cap.

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.

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

Warm up the engine.

Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

Reinstall the radiator cap.

Install the reinforcement with the 4 bolts.

Torque:

96 N*m{978 kgf*cm, 71 ft.*lbf}

Install the under cover with the 2 clips.

Install the under cover with the 2 bolts, 4 screw and 12 clips.