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Installation [12/2021 - ]: Procedure

  1. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT 
    1. GTY1133448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 1.0 to 7.0 mm (0.0394 to 0.276 in.) *d 45°
      *e Upper Side *f Front Side
      *g LH Side - -
      1. Install a new gasket to the thermostat.
      2. Connect the No. 4 water by-pass hose to the water inlet sub-assembly with thermostat and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 4 water by-pass hose is securely inserted to the stopper.
      3. Install the water inlet sub-assembly with thermostat to the cylinder block assembly with the 4 bolts.

        Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

      4. Connect the No. 4 water by-pass hose to the No. 1 water by-pass pipe assembly and slide the hose clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and the paint mark on the pipe are securely overlapped.
        • Make sure the No. 4 water by-pass hose is securely inserted to the stopper.
  2. INSTALL WATER OUTLET PIPE WITH WATER BY-PASS JOINT 
    1. Fig 1: Water Outlet Pipe With Water By-Pass Joint Bolts Tightening Sequence
      GTY1081205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b 1.0 to 7.0 mm (0.0394 to 0.276 in.)
      *c 90° *d Upper Side
      *e LH Side - -
      Bolt A Bolt B
      1. Install 2 new gaskets to the water outlet pipe with water by-pass joint.
      2. Tighten the 6 bolts in the order shown in the illustration.

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      3. Connect the No. 9 water by-pass hose to the water outlet pipe with water by-pass joint and slide the clip to secure it as shown in the illustration.
  3. CONNECT NO. 14 WATER BY-PASS HOSE 
    1. GTY1080776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 1.0 to 7.0 mm (0.0394 to 0.276 in.) *d 60°
      *e 15° *f Upper Side
      *g Rear Side - -
      1. Connect the No. 14 water by-pass hose to the water inlet sub-assembly with thermostat and slide the clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 14 water by-pass hose is securely inserted to the stopper.
  4. CONNECT NO. 5 WATER BY-PASS HOSE 
    1. GTY1081141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 1.0 to 7.0 mm (0.0394 to 0.276 in.) *d 90°
      *e Front Side *f RH Side
      1. Connect the No. 5 water by-pass hose to the water outlet pipe with water by-pass joint and slide the clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and the paint mark on the pipe are securely overlapped.
        • Make sure the No. 5 water by-pass hose is securely inserted to the stopper.
  5. CONNECT WATER BY-PASS HOSE 
    1. GTY1081292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 1.0 to 7.0 mm (0.0394 to 0.276 in.) *d 90°
      *e Upper Side *f LH Side
      1. Connect the water by-pass hose to the water outlet pipe with water by-pass joint and slide the clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and the paint mark on the pipe are securely overlapped.
        • Make sure the water by-pass hose is securely inserted to the stopper.
  6. INSTALL WATER INLET PIPE WITH WATER BY-PASS HOSE 
    1. GTY1080846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 1.0 to 7.0 mm (0.0394 to 0.276 in.) *d 90°
      *e Upper Side *f Front Side
      1. Connect the water inlet pipe with water by-pass hose to the water inlet sub-assembly with thermostat and slide the clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the water by-pass hose is securely inserted to the stopper.
      2. Install the water inlet pipe with water by-pass hose to the alternator bracket sub-assembly with the 2 bolts.

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  7. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. GTY1130163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Stopper
      *c 2.0 to 5.0 mm (0.0787 to 0.197 in.) *d 25°
      *e Front Side *f RH Side
      1. Connect the No. 4 water by-pass hose to the water inlet pipe and slide the clip to secure it as shown in the illustration.
        NOTE:
        • Install so that the paint mark and positioning stopper are securely overlapped.
        • Make sure the No. 4 water by-pass hose is securely inserted to the stopper.
  8. INSTALL NO. 3 AIR HOSE 
    Refer to PROCEDURE - Step 26
  9. INSTALL NO. 1 AIR HOSE 
    Refer to PROCEDURE - Step 12
  10. INSTALL NO. 2 AIR TUBE ASSEMBLY 
    Refer to PROCEDURE - Step 8
  11. INSTALL NO. 1 AIR TUBE ASSEMBLY 
    Refer to PROCEDURE - Step 9
  12. INSTALL COOLING FAN WIRE 
    See step  30
  13. CONNECT NO. 2 RADIATOR HOSE 
    See step  34
  14. INSTALL NO. 1 RADIATOR HOSE 
    See step  36
  15. CONNECT ENGINE WIRE 

    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  16. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
    See step  37
  17. CONNECT NO. 2 WATER BY-PASS HOSE 
    See step  38
  18. CONNECT WATER BY-PASS HOSE ASSEMBLY 
    See step  39
  19. CONNECT WATER BY-PASS HOSE 
    See step  40
  20. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE ASSEMBLY LH 
    Refer to PROCEDURE - Step 15
  21. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE ASSEMBLY RH 
    Refer to PROCEDURE - Step 16
  22. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 3

  23. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 3

  24. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 3

  25. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  26. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
    Refer to PROCEDURE - Step 7
  27. INSTALL V-BANK COVER SUB-ASSEMBLY 
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