Toyota 90916-03136
Thermostat

Quieting down the engine coolant is the initial step to perform thermostat maintenance. The first action involves water inlet removal through unfastening two nuts before disconnecting the cylinder block. After the coolant evacuation step, proceed to remove the thermostat. The installation process begins with a new gasket applied to the thermostat followed by placing it in position with the jiggle valve oriented upward throughout a 10 degrees range near its recommended spot. For water inlet repair install the 2 nuts while tightening them to 9.0 Nm (92 kgf-cm, 80 inch lbs.). The last step includes engine coolant addition while inspecting for leakage.

The starting point for removing the thermostat is to uninstall the No. 1 engine under cover. Next, drain the engine coolant. Remove the outlet radiator hose as the following step. Proceed to eliminate the inlet water by unfastening its 2 nuts to disconnect it from the cylinder block. Then take off the thermostat while also detracting the gasket attached to it.

The first step of installing the 2AZ-FE cooling system thermostat requires the placement of a new gasket while setting the jiggle valve to face upward with adjustable angles between 10 degrees on each side of the recommended position. Lead by placing the water inlet nuts on the thermostat then secure them with 9.0 Nm (92 kgf-cm, 80 in-lbf) torque. Last touches include attaching the radiator hose outlet followed by adding engine coolant before checking for cooling system leaks. Install the engine under cover LH followed by engine under cover RH together with front wheel opening extension pad LH and front wheel opening extension pad RH.

The service and repair process of the thermostat starts with removing the No. 1 engine under cover before draining engine coolant. Proceed with the removal of the radiator support opening cover followed by disconnecting the No. 2 radiator hose. Dismantle the water inlet by removing the 2 nuts while detaching it from the cylinder block and then remove the thermostat with its attached gasket. Dip the thermostat into water during examination and heat it slowly to verify the valve opens at 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit) as replace the thermostat if necessary. Verify that the thermostat valve produces at least 10 mm (0.39 inch) opening at 95 (203 degrees Fahrenheit) while having complete closure below 77 degrees Celsius (171 degrees Fahrenheit) if any of these specifications are not met then replace the thermostat. The installation method includes setting the new gasket on the thermostat before placing the jiggle valve in an upward position while maintaining a 10 degrees tolerance. Secure the water inlet installation with the 2 nuts at 9.0 Nm (92 kgf-cm, 80 inch lbs.), fasten the No. 2 radiator hose and check for coolant leaks while filling the engine with coolant. You must replace the radiator support opening cover and the No. 1 engine under cover in the last step.

Add engine coolant and check for any coolant leakage.

Connect the outlet radiator hose, add engine coolant, and inspect for any coolant leaks.

Position the thermostat with the jiggle valve facing upward, which can be adjusted within 10° on either side of the prescribed position.

Apply a torque of 9.0 Nm (92 kgf-cm, 80 in-lbf).

Check the valve opening temperature, which should be between 80 to 84°C (176 to 183°F); if it does not meet this standard, replace the thermostat.

Attach the water inlet using the 2 nuts, tightening them to a torque of 9.0 Nm (92 kgf-cm, 80 in-lbf).

A slight adjustment of up to 10° in either direction from the prescribed position.

Remove the thermostat and take off the gasket from it.

Place a new gasket onto the thermostat and ensure the jiggle valve is facing upward, noting that it may be set within 10° on either side of the prescribed position.

First install a new gasket to the thermostat and position it with the jiggle valve facing up.

The jiggle valve can be adjusted within 10° on either side of the indicated position.

Remove the engine under covers on the left and right.

Remove the thermostat and its gasket.

Disconnect the No. 2 radiator hose.

Drain the engine coolant.

Remove the water inlet by taking off the 2 nuts to disconnect it from the cylinder block.

Remove the fan and generator V belt, followed by the generator assembly.

Take off the 2 nuts and disconnect it from the cylinder block.

Add engine coolant and check for any leaks.

Take off the radiator hose inlet and remove the water inlet by disconnecting it from the cylinder block after removing the 2 nuts.

Install the fan and generator V belt.

Remove the fan and generator V belt, followed by the generator assembly.