INSTALLATION

Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing.

HINT:

The jiggle valve should be set within +-15° from the prescribed position.

Torque:

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

Apply soapy water to the O-ring.

Connect the water inlet pipe to the water inlet.

Install the bolt which is used to fix the water inlet pipe to the cylinder head with the bolt.

Torque:

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

Torque:

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

NOTICE:

2 people are needed to install the w/ converter inverter assembly.

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Connect the engine wire No.4 with the bolt to the w/ converter inverter assembly.

Torque:

5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

NOTICE:

1. Make sure that the connectors are fully engaged.
   
2. Make sure that the bolts are fully tightened.
   

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

Torque:

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

Torque:

6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

Torque:

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

Torque:

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

Connect the 2 wire harness clamps to the air cleaner.

Install the air cleaner filter element to the air cleaner case.

Torque:

7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

Install the 4 clips and cool air intake duct seal.

Remove the 4 shock absorber nuts.

Torque:

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

Install the 4 shock absorber nuts (B).

Torque:

80 N*m{ 815 kgf*cm , 59 ft.*lbf }

Install the wire harness clamp and grommet (A).

Torque:

7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

Connect the connector.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

Operate the front wipers while spraying water or washer fluid on the windshield.

Make sure that the wipers function properly and there is no interference with the vehicle body.

Push down on the grip to lock.

Close the battery service hole cover.

NOTICE:

Check that the 2 battery service hole cover clips are securely connected to the battery carrier bracket (click sound).

NOTICE:

Insert one end of the hose into the reserve tank.

Add coolant from the reserve tank.

Coolant quantity:

3.4 L (3.6 US qts, 3.0 Imp. qts.)

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to the ON position.
   

3. Select the inspection mode (Click here).
   

4. On the tester, enter the following menus: Powertrain / Hybrid Control / Active test / Water Pump.
   

5. Keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds.
   

   Standard:

   Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.
   

   HINT:

   Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

When not using the intelligent tester:

1. Put the vehicle into the READY-on state. [*1]
   

2. Turn the ignition switch off and add coolant to the FULL level because the coolant level drops as the air bleeds. [*2]
   

   NOTICE:

   1. Be sure to turn the ignition switch off before adding LLC.
      
   2. Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.
      

3. Repeat steps [*1] and [*2] until air bleeding from the coolant system is completed.
   

   Standard:

   Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.
   

   HINT:

   Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

When the air is completely bled from the coolant system, tighten the plug.

Tighten the lower drain plug of the radiator.

Loosen the upper drain plug of the radiator.

Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

Tighten the upper drain plug.

CAUTION:

1. Do not use an alcohol type coolant or plain water alone.
   
2. The coolant must be mixed with plain water (preferably de-mineralized water).
   

   Capacity:

   9.7 liters (10.3 US qts, 8.5 lmp.qts)
   

HINT:

1. Improper coolants may damage engine cooling system.
   
2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
   
3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
   
4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.
   

Install the radiator cap securely.

Fill the radiator reservoir tank with coolant.

Warm up the engine.

HINT:

Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

Stop the engine and wait until the coolant cools down.

Remove the radiator cap and check the coolant level inside the radiator.

If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

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

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 118 kPa (1.2 kgf*cm, 17 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.

Some system need initialization when reconnecting the battery cable. (Click here)