Engine Oil Cooler Installation

Install 2 new gaskets and the oil cooler to the filter bracket with the 4 nuts.

Torque:

15.5 N*m{158 kgf*cm, 11 ft.*lbf}

Install a new gasket and oil filter bracket with the 10 bolts and 2 nuts.

Torque:

29.5 N*m{301 kgf*cm, 22 ft.*lbf}

Check and clean the oil filter installation surface.

Apply clean engine oil to the gasket of a new oil filter.

Install the oil filter, and tighten it by hand until the gasket contacts the installation surface.

Using SST, tighten the oil filter by an additional 3/4 turn to seat the filter.

SST

09228-44011

Install a new gasket to the cylinder head.

HINT:

Be sure to install a new gasket in the correct direction as shown in the illustration.

Install the exhaust manifold with the 6 bolts and 2 new nuts. Uniformly tighten the bolts and nuts in several steps.

Torque:

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

Install the front exhaust pipe (Toyota Fortuner RM000001KYS002X_01_0001.html).

Install the heat insulator with the 3 bolts.

Torque:

18 N*m{185 kgf*cm, 13 ft.*lbf}for bolt A

19 N*m{195 kgf*cm, 14 ft.*lbf}for bolt B

Install the generator with the bolt.

Torque:

75 N*m{765 kgf*cm, 55 ft.*lbf}

Connect the vacuum oil outlet hose.

Install 2 new gaskets and the vacuum pump hose with the union bolt.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Install the vacuum pump oil inlet hose with 2 new gaskets and the union bolt.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Attach the vacuum pump oil inlet hose to the cord clip.

Install the generator wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Attach the terminal cap.

Connect the generator connector.

Connect the vacuum pump oil inlet hose with 2 new gaskets and the union bolt.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

HINT:

When tightening the inlet hose, hang the stopper-bar of the inlet hose on the filter bracket to prevent the inlet hose from rotating.

Temporarily install the compressor mounting bracket with the 4 bolts.

Using several steps, uniformly install and tighten the 4 bolts.

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

Temporarily install the spacer with the bolt.

Install the compressor with the 4 bolts and tighten the bolts in the order shown in the illustration.

Torque:

24.5 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the connector.

Install the V belt.

Tightening bolt C, adjust the deflection of the V belt (Toyota Fortuner RM000001KYZ001X_01_0001.html).

Tighten the bolts A and B.

Torque:

75 N*m{765 kgf*cm, 55 ft.*lbf}for bolt A

18 N*m{185 kgf*cm, 13 ft.*lbf}for bolt B

Recheck the deflection of the V belt.

Install the V belt.

Using a bar, adjust the tension of the V belt.

Tighten the bolts A and B.

Torque:

75 N*m{765 kgf*cm, 55 ft.*lbf}for bolt A

18 N*m{185 kgf*cm, 13 ft.*lbf}for bolt B

Check the deflection of the V belt (Toyota Fortuner RM000001KYZ001X_01_0001.html).

Install the V belt.

Tightening bolt B, adjust the deflection of the V belt (Toyota Fortuner RM000001KYZ001X_01_0001.html).

Tighten nut A.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Recheck the deflection of the V belt.

Install the V belt.

Using a bar, adjust the deflection of the V belt (Toyota Fortuner RM000001KYZ001X_01_0001.html).

Tighten bolt A and nut B.

Torque:

48 N*m{489 kgf*cm, 35 ft.*lbf}for bolt A

64 N*m{635 kgf*cm, 47 ft.*lbf}for bolt B

Recheck the deflection of the V belt.

Install the intake pipe with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Tighten the intake pipe clamp.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the connector to the IAT sensor.

Connect the hose clamp.

Add fresh engine oil.

Standard capacity:

Item	Specified Condition
Drain and refill with oil filter change	7.2 liters (7.6 US qts, 6.3 Imp. qts)
Drain and refill without oil filter change	6.7 liters (7.1 US qts, 5.9 Imp. qts)
Dry fill	8.4 liters (8.9 US qts, 7.4 Imp. qts)

Install the oil filler cap.

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

57 N*m{581 kgf*cm, 42 ft.*lbf}

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's FULL line.

Standard capacity:

9.4 liters (9.9 US qts, 8.3 Imp. 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. Please contact your TOYOTA dealer for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the LOW line, add TOYOTA SLLC to the FULL line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

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

2. Maintain the engine speed at 2,500 to 3,000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing 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.
      

4. Stop the engine and wait until the 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.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the LOW line, add TOYOTA SLLC to the FULL line.

Start the engine, and check that there are no oil leaks after performing maintenance.

Check for engine coolant leaks (Toyota Fortuner RM000001443007X_01_0001.html).

Install the under cover with the 2 bolts.

Torque:

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

Install the under cover with the 4 bolts.

Torque:

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