REPLACEMENT

CAUTION / NOTICE / HINT

CAUTION:

Do not remove the reserve tank cap, radiator cap sub-assembly, air release valve or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

PROCEDURE

1. DRAIN ENGINE COOLANT (for Fully Sealed Type)

CAUTION:

Do not remove the reserve tank cap, air release valve or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

(a) Remove the 3 clips and bolt.

(b) Pull down the No. 1 engine under cover assembly.

NOTICE:

Do not damage the No. 1 engine under cover assembly.

(c) Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.

*a Hose

(d) Loosen the radiator drain cock plug.

(e) Remove the reserve tank cap. Then drain the engine coolant.

HINT:

Collect the engine coolant in a container and dispose of it according to the regulations in your area.

(f) Tighten the radiator drain cock plug by hand.

(g) Disconnect the hose from the radiator drain cock.

(h) Install the 3 clips.

(i) Install the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

2. DRAIN ENGINE COOLANT (for Non-Fully Sealed Type)

CAUTION:

Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

(a) Remove the 3 clips and bolt.

(b) Pull down the No. 1 engine under cover assembly.

NOTICE:

Do not damage the No. 1 engine under cover assembly.

(c) Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.

*a Hose

(d) Loosen the radiator drain cock plug.

(e) Remove the radiator cap sub-assembly. Then drain the engine coolant.

HINT:

Collect the engine coolant in a container and dispose of it according to the regulations in your area.

(f) Tighten the radiator drain cock plug by hand.

(g) Disconnect the hose from the radiator drain cock.

(h) Install the 3 clips.

(i) Install the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

3. ADD ENGINE COOLANT (for Fully Sealed Type)

(a) Using a 6 mm hexagon socket wrench, remove the air release valve from the radiator reserve tank assembly.

*a Air Release Valve

(b) Add engine coolant to the level shown in the illustration. Standard Capacity: Item Specified Condition for CVT 6.2 liters (6.6 US qts, 5.5 Imp. qts) for Manual Transaxle 5.9 liters (6.2 US qts, 5.2 Imp. qts) NOTICE: Do not substitute plain water for engine coolant. HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).

(c) Using a 6 mm hexagon socket wrench, install the air release valve to the radiator reserve tank assembly.

Torque:

2.0 N·m {20 kgf·cm, 18 in·lbf}

(d) Install the reserve tank cap.

NOTICE:

Securely tighten the reserve tank cap as much as possible.

(e) Perform the following procedure to set the engine to engine coolant filling mode.

HINT:

It is necessary to set the engine to engine coolant filling mode to ensure that a certain engine water pump assembly (water inlet housing) speed is maintained in order to circulate engine coolant.

(2) Start the engine.

(3) Run the engine at 1500 rpm or more for 15 seconds or more.

(4) Check that the speed of the electric water pump increases when the engine is raced to 3000 rpm.

Powertrain > Engine > Data List

Standard:

HINT:

The speed of the engine water pump assembly (water inlet housing) changes in accordance with the engine speed when the engine is being raced in engine coolant filling mode.

(f) Bleed air from the cooling system.

(1) Warm up the engine until the water inlet with thermostat sub-assembly opens. While the water inlet with thermostat sub-assembly is open, circulate the engine coolant for several minutes.

HINT:

The water inlet with thermostat sub-assembly open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

(2) After the engine has warmed up, run the engine using the following cycle for at least 7 minutes: at 3000 rpm for 5 seconds, at idle speed for 45 seconds. (Repeat this cycle at least 8 times.)

(3) Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the system.

CAUTION:

When squeezing the No. 1 radiator hose and No. 2 radiator hose:

HINT:

If the flowing sound of engine coolant can still be heard after bleeding air, perform the following procedure to bleed air again.

(g) After the engine has cooled down, check that the engine coolant level is between the FULL and LOW lines. NOTICE: The coolant levels in the compartments inside the radiator reserve tank assembly may differ, but this is not a malfunction. If the engine coolant level is below the LOW line, add engine coolant to the FULL line.

*a FULL Line *b LOW Line

4. ADD ENGINE COOLANT (for Non-Fully Sealed Type)

(a) Slowly fill the radiator assembly with engine coolant.

Standard Capacity:

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).

(b) Remove the reserve tank cap. [*1]

(c) Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the MAX line. [*2] NOTICE: Do not substitute plain water for engine coolant.

*a MAX Line *b MIN Line

(d) Install the reserve tank cap. [*3]

(e) Install the radiator cap sub-assembly.

NOTICE:

Securely tighten the radiator cap sub-assembly.

(f) Perform the following procedure to set the engine to engine coolant filling mode. [*4]

HINT:

It is necessary to set the engine to engine coolant filling mode to ensure that a certain engine water pump assembly (water inlet housing) speed is maintained in order to circulate engine coolant.

(2) Start the engine.

(3) Run the engine at 1500 rpm or more for 15 seconds or more.

(4) Check that the speed of the electric water pump increases when the engine is raced to 3000 rpm.

Powertrain > Engine > Data List

Standard:

HINT:

The speed of the engine water pump assembly (water inlet housing) changes in accordance with the engine speed when the engine is being raced in engine coolant filling mode.

(g) Bleed air from the cooling system. [*5]

(1) Warm up the engine until the water inlet with thermostat sub-assembly opens. While the water inlet with thermostat sub-assembly is open, circulate the engine coolant for several minutes.

HINT:

The water inlet with thermostat sub-assembly open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

(2) After the engine has warmed up, run the engine using the following cycle for at least 7 minutes: at 3000 rpm for 5 seconds, at idle speed for 45 seconds. (Repeat this cycle at least 8 times.)

(3) Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the system.

CAUTION:

When squeezing the No. 1 radiator hose and No. 2 radiator hose:

(h) Wait until the engine coolant cools down. [*6]

(i) Check that the engine coolant level is between the MAX line and MIN line. [*7]

HINT:

If the flowing sound of engine coolant can still be heard after bleeding air, perform the following procedure to bleed air again.

5. INSPECT FOR COOLANT LEAK (for Fully Sealed Type)

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6. INSPECT FOR COOLANT LEAK (for Non-Fully Sealed Type)

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