THERMOSTAT > INSTALLATION

for Preparation Click here



1. INSTALL WATER INLET

  1. Install a new gasket to the water inlet.



    A198906

  1. Install the water inlet with the 2 nuts.

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



2. CONNECT NO. 2 RADIATOR HOSE


    A201677E02

  1. Connect the radiator hose to the water inlet with the hose clip.
    Text in Illustration 
    *a
    		View A
    *b
    		Upper Side
    *c
    		Yellow Paint Mark
    *d
    		Projection On Water Inlet

    NOTICE:
    Perform the installation with the hose clip and mark at the correct angle.



3. INSTALL NO. 1 WATER BY-PASS PIPE


    A201675E03

  1. Install a new gasket as shown in the illustration.
    Text in Illustration 
    *1
    		Gasket
    *2
    		Water By-pass Pipe Flange
    *a
    		Upper Side

  1. Coat the contact surface of the new O-ring and the water by-pass pipe with a sufficient amount of the coolant ("TOYOTA Super Long Life Coolant").

  1. Insert the water by-pass pipe into the water inlet.

  1. Temporarily tighten the bolt and install the 2 nuts.

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

  1. Tighten the bolt.

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



4. INSTALL GENERATOR ASSEMBLY
(Click here)


5. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    A198883

  1. Install the air cleaner filter element as shown in the illustration.



6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

  1. Align the 2 hinges with the guides on the case and engage them in the grooves.

  1. Install the air cleaner cap with the 2 clamps.



    A205327E03

  1. Connect the air cleaner hose as shown in the illustration.
    Text in Illustration 
    *a
    		View A
    *b
    		Upper Side
    *c
    		Front Side
    *d
    		Recession
    *e
    		Protrusion

    HINT:
    The clamp should contact the air cleaner hose stopper.



7. ADD ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)

  1. Tighten the water inlet drain cock plug.



    A201667

  1. Plunge the engine drain cock plug.



    A201665E01

  1. Install the water inlet clip.
    Text in Illustration 
    *1
    		Water Inlet Clip
    *2
    		Hose

  1. Disconnect the hose from the water inlet drain cock plug.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		4.5 liters (4.8 US qts, 4.0 Imp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    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 is a combination of low phosphates and organic acids).

  1. 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.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler cap sub-assembly.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


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

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      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.

  1. Stop the engine, and wait until the engine coolant cools down.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *a
    		FULL Line
    *b
    		LOW Line



8. ADD ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)

  1. Tighten the radiator drain cock plug.

  1. Remove the water filler cap sub-assembly.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		4.5 liters (4.8 US qts, 4.0 Imp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    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 is a combination of low phosphates and organic acids).

  1. 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.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler cap sub-assembly.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


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

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      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.

  1. Stop the engine, and wait until the engine coolant cools down.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *a
    		FULL Line
    *b
    		LOW Line



9. INSPECT FOR COOLANT LEAK

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.



    A198898E01

  1. Fill the radiator assembly with engine coolant, and attach a radiator cap tester.
    Text in Illustration 
    *1
    		Radiator Cap Tester

  1. Pump the 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 assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.