Thermostat (For Hatchback) Installation

Install a new gasket onto the thermostat.

Install the thermostat with the jiggle valve facing upward.

HINT:

The jiggle valve may be set within 10° of vertical in either direction, as shown in the illustration.

Install the water inlet with radiator hose with the 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Tighten the cylinder block drain cock plug and the radiator drain cock plug.

Torque:

13 N*m{133 kgf*cm, 9.6 ft.*lbf}

Pour engine coolant into the radiator assembly until it is full.

Standard capacity:

5.0 liters (5.3 US qts, 4.4 Imp. qts)

NOTICE:

Do not substitute water for coolant.

HINT:

1. Use of improper engine coolant may damage the engine coolant system.
   
2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).
   

Check the coolant level inside the radiator assembly by squeezing the No. 2 radiator hose and the No. 3 radiator hose several times by hand. If the coolant level goes down, add engine coolant.

Install the water filler cap sub-assembly securely.

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

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.
   

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the coolant starts to flow inside the hose.

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the No. 2 radiator hose and No. 3 radiator hose several times by hand to bleed air.
   

   CAUTION:

   When pressing 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.

If the coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the coolant level stays at the full level.

Recheck the coolant level inside the radiator reservoir tank assembly. If it is below the full level, add coolant.

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

Pump the tester to 137 kPa (1.4 kgf/cm², 19.9 psi), then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.