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Engine Cooling System (Hybrid): Thermostat: Installation

  1. INSTALL THERMOSTAT 
    1. Install a new gasket to the thermostat.
    2. 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.

      Fig 1: Aligning Jiggle Valve Of Thermostat And Water Inlet
      G05201043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL WATER INLET 
    1. Install the 3 nuts and the water inlet.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 2: Locating Water Inlet With Nuts
      G05201042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL WATER INLET PIPE 
    1. Install a new O-ring to the water inlet pipe.
    2. Apply soapy water to the O-ring.
    3. Connect the water inlet pipe to the water inlet.
    4. 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) 

      Fig 3: Locating Water Inlet Pipe
      G05201041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL W/CONVERTER INVERTER ASSEMBLY  (See INSTALLATION )
  5. INSTALL INVERTER BRACKET NO.4  (See INSTALLATION )
  6. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY  (See INSTALLATION )
  7. REMOVE INVERTER COVER  (See INSTALLATION )
  8. CONNECT NO.3 WIRE FRAME  (See INSTALLATION )
  9. CONNECT MG ECU CONNECTOR  (See INSTALLATION )
  10. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR  (See INSTALLATION )
  11. CONNECT ENGINE WIRE NO.4  (See INSTALLATION )
  12. CHECK HIGH VOLTAGE CABLE CONNECTION  (See INSTALLATION )
  13. INSTALL INVERTER COVER  (See INSTALLATION )
  14. INSTALL POWER STEERING ECU BRACKET  (See INSTALLATION )
  15. CONNECT WATER HOSE  (See INSTALLATION )
  16. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY  (See INSTALLATION )
  17. CONNECT ENGINE ROOM WIRE NO.2  (See INSTALLATION )
  18. CONNECT CIRCUIT BREAKER SENSOR NO.1  (See INSTALLATION )
  19. INSTALL POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  20. INSTALL INVERTER BRACKET NO.5  (See INSTALLATION )
  21. INSTALL AIR CLEANER W/RESONATER  (See INSTALLATION )
  22. INSTALL AIR CLEANER CAP W/INLET  (See INSTALLATION )
  23. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER  (See INSTALLATION )
  24. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  26. ADD HYBRID VEHICLE COOLANT  (See REPLACEMENT , for P310 and REPLACEMENT , for Q211)
  27. ADD ENGINE COOLANT (See  ON-VEHICLE INSPECTION   ) 
  28. CHECK HYBRID VEHICLE COOLANT LEAKS 
  29. INSPECT FOR COOLANT LEAK (See  ON-VEHICLE INSPECTION   ) 
  30. INSTALL ENGINE ROOM SIDE LH COVER NO.2  (See INSTALLATION )
  31. PERFORM INITIALIZATION  (See INSTALLATION )
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