Toyota 90916-A3003
Water Inlet

Draining engine coolant must be the first step when replacing the 2AZ-FE thermostat. The water inlet needs removal after unscrewing the 2 nuts to release it from the cylinder block. Position the thermostat with its jiggle valve aimed upward after seaming a new gasket against it while maintaining a placement within 10 degrees of the recommended location on both sides. Reinstall the water inlet by tightening it to 9.0 Nm (92 kgf-cm, 80 inch lbs.). Last step is to put in engine coolant while inspecting for fluid leaks.

The first step to install the 2ZR-FE cooling system thermostat involves placing a new gasket onto the thermostat before positioning the jiggle valve upward. You can set the valve between 10 degrees on either side. The 2 nuts on the water inlet should be tightened to a torque value of 10 Nm (102 kgf-cm, 7 ft-lbf) when connecting it to the radiator hose. Engine coolant should be added after installation and all installed components need a thorough leak inspection.

Service and repair of the thermostat begins by pulling out all engine coolant. The oil filter should be removed only if an oil cooler is present on the vehicle. Begin the service by removing the two nuts from the water inlet on the water pump cover before removing the thermostat with its gasket. Inspection requires the thermostat to be submerged in water before gradual heating until the valve opens at 80 - 84 degrees Celsius (176 - 183 degrees Fahrenheit) which determines the need to replace it. A proper replacement of the thermostat becomes necessary when the valve lift measures less than 8 mm (0.31 inch) at 95 degrees Celsius (203 degrees Fahrenheit). A replacement thermostat should be installed when the valve remains open below 40 degrees Celsius (104 degrees Fahrenheit). Place the thermostat in the water inlet along with a new gasket while physically aligning its jiggle valve with the protrusion on the water inlet so that the positions permit a 5 degrees tolerance. Mount the water inlet and thermostat with two nuts while torquing them to 8.8 Nm which is equivalent to 90 kgf.cm or 78 inch lbs. After installing the oil filter users should fill the system with engine coolant when their vehicles are equipped with an oil cooler. Begin engine operation then examine for coolant leakage followed by verification of engine oil amount.

The servicing process for the thermostat includes draining away engine coolant as the first step. First remove the fan together with the generator V belt before separating the generator assembly. Start by disconnecting the radiator hose inlet before removing the water inlet through the process of unscrewing the 2 nuts which separates it from the cylinder block. Proceed to remove the thermostat. Install a new gasket to the thermostat before positioning it with the jiggle valve facing upward while keeping in mind that the valve can be set at 10° on either side of its designated location. Familiarize the water inlet with 2 nuts before securing them to complete a torque of 9.0 Nm (92 kgf-cm, 80 inch lbs.). Install the radiator hose inlet followed by the generator assembly and fan and generator V belt. Place engine coolant in the system before inspecting for fluid leakage.

Servicing and repairing the thermostat requires the engine coolant drainage followed by generator and drive belt removal. The water inlet from the cylinder block needs removal through unthreading of the two nuts before extracting the thermostat along with its gasket. The inspection procedure includes testing the thermostat in water until its valve opening temperature reaches between 80.0 - 84.0 degrees Celsius (176 - 183 degrees Fahrenheit). C (176 - 183 degrees The service requires replacement of the thermostat unless it meets the defined valve opening temperature range (80.0 - 84.0 degrees Celsius / 176 - 183 degrees Fahrenheit). The valve lift must reach at least 10 millimeter (0.39 inch) when the temperature reaches 90 degrees Celsius. C (194 degrees The valve must prove its complete closure to waterflow below 40 degrees Fahrenheit (40 degrees Celsius). C (104 degrees The thermostat needs replacement when checking conditions reveal either that the valve lift does not reach 10mm or the valve opening occurs outside of 80.0 to 84.0F (176 to 183F). Before installing the thermostat insert it into the cylinder block combined with a fresh gasket while rotating the jiggle valve upwards towards the desired position that can exist within a 10-degree range. You must attach the water inlet using its two nuts followed by torqueing them to 10 Nm (100 kgf-cm, 7 ft. lbs.) then reattach the generator and drive belt. After filling the engine with coolant start the engine while checking for coolant is leaking properly.

The repair and servicing process starts with engine under cover RH removal then draining engine coolant subsequently unfastening the generator V belt and generator assembly followed by the thermostat removal. The first step involves removing the water inlet by unfastening its 2 nuts then it becomes ready for thermostat detachment. You should inspect the thermostat valve opening temperature which is marked on the device by submerging it in water while gradually heating it until the temperature falls within 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit). Replace the thermostat whenever its valves do not open to a suitable temperature range between 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit). A proper replacement of the thermostat should be considered if the valve lift reveals less than 10 mm (0.39 inch) during the 95 degrees Celsius (203 degrees Fahrenheit) inspection. Use replacement thermostats whenever the valve remains open at temperatures below 77 degrees Celsius (171 degrees Fahrenheit). The installation procedure starts with applying a new gasket on top of the thermostat before installation where you should position the jiggle valve vertically upwards while keeping in mind it can be placed between 10 degrees angles on either side of its correct orientation. After placing the generator assembly the water inlet should be installed with 2 nuts which need to be torqued to 11 Nm (112 kgf-cm, 8 ft. lbs.). Place engine coolant into the system while searching for coolant leaks before installing the right-hand engine under cover.

The service procedure for the thermostat requires the engine coolant drainage followed by drive belt generator removal and front engine under cover disassembly. You must detach the water inlet from the cylinder block by taking out both nuts before extracting the thermostat while taking out its gasket. The thermostat requires inspection through water submersion while raising temperature until the valve opens at 80 to 84 degrees Celsius between 176 to 183.2 degrees Fahrenheit then replace the part if the opening temperature does not meet the specification. Test the valve lift's opening by checking if it exceeds 10 mm (0.39 inch) at 90 degrees Celsius (194 degrees Fahrenheit) and at the same time verify complete valve closure below 40 degrees Celsius (104 degrees Fahrenheit). If any criterion fails, replace the valve immediately. Place the thermostat inside the cylinder block using a new gasket while maintaining the jiggle valve in an upward position within a 10 degrees range and either side of the specified positioning. Begin by tightening the water inlet with two nuts according to 9 Nm of torque which equates to 92 kgf-cm or 80 inch lbs. After that re-attach the front engine under cover with the generator and drive belt. To complete the operation you should fill the system with engine coolant then start the engine to check for leaks followed by another inspection of the engine coolant amount.

Services on the thermostat begin with removing the engine under cover RH and draining engine coolant before taking off the fan and generator V belt and generator assembly. The service starts with the removal of water inlet through nuts detachment followed by thermostat extraction. The thermostat inspection process starts with measuring the temperature value on the valve and then placing it in water before heating the liquid until the valve opens at 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit). The replacement of the thermostat should take place when the valve opening temperature falls outside the specified area of 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit). A new thermostat needs installation if the valve fails to achieve a lift of 10 mm (0.39 in.) when the system reaches 95 degrees Celsius (203 degrees Fahrenheit). The thermostat requires replacement when any temperature below 77 degrees Celsius (171 degrees Fahrenheit) permits gas to flow from the valve. Location the new gasket on the thermostat before installation while keeping the jiggle valve pointed up and giving it room for a 10-degree angle. Install the water inlet by tightening its two nuts to 11 N m torque (112 kgf cm or 8 ft. lbf) and then fasten the generator assembly. The procedure ends with the installation of engine under cover RH after reviewing all coolant leaks and adding coolant.

Engine coolant drainage is the first step when servicing or repairing the thermostat. After draining engine coolant you should take off the fan and generator V belt and finally disconnect the generator assembly. Disassemble the radiator hose inlet before unconnecting the water inlet from the cylinder block once you remove its 2 nuts. Proceed to remove the thermostat. Immersion of the thermostat in water requires a slow heating process during inspection to check for valve opening temperatures between 80 to 84 degrees Celsius (176 to 183 degrees Fahrenheit). A new thermostat needs installation when the temperature range is not met. The thermostat needs replacement once the valve lift measurement is below 10 mm (0.394 inch) at 95 degrees Celsius (203 degrees Fahrenheit) or if the valve fails to close completely when the temperature drops to 40 degrees Celsius (104 degrees Fahrenheit). Put a new gasket on the thermostat first before installing it at an upward angle with the jiggle valve positioned correctly to allow 10 degrees variance. Install the water inlet by applying 9.0 Nm torque on the 2 nuts before adding the radiator hose inlet and generator assembly and fan and generator V belt. Into the system you must put engine coolant while inspecting for fluid leakage.

Service on the thermostat begins by draining coolant followed by battery removal paired with cleaning all air cleaning components including the cap sub-assembly and filter element sub-assembly and both air inlet and case components and bracket and inlet and starter assembly. The water inlet service starts with removing the radiator hose outlet then unfastening the wire harness clamp followed by three nut and bolt removal to separate the water inlet. After that, remove the thermostat. New gasket placement on the thermostat should have the jiggle valve directed toward the upper stud bolt before inserting the thermostat into the water inlet housing while keeping the jiggle valve between 150 of either side of its recommended position. Install the water inlet while tightening its nut to 8.0 Nm (82 kgf-cm, 71 inch lbs.) alongside the bolt with 20 Nm (199 kgf-cm, 14 ft. lbs. torque). The repair process continues with starter assembly installation followed by air cleaner inlet numbers 1 and 2 and their corresponding components including air cleaner bracket and air cleaner case and air cleaner cap sub-assembly. Complete the procedure by adding coolant before checking the system for any engine coolant leakage.

The first step to remove the thermostat involves disconnecting the negative battery cable but some systems might require initialization post-reconnection. The technician starts by removing the No. 1 engine cover sub-assembly followed by cool air intake duct seal and both the No. 1 engine under cover and No. 2 engine under cover. Pull out all engine coolant before eliminating the V-ribbed belt from the system. Disconnect the wire harness clamp bracket followed by removal of the generator assembly. Start by taking off the No. 2 radiator hose after which you remove the water inlet by unfastening its 2 nuts and extracting the water inlet itself. To complete the task remove the thermostat together with its gasket.

Remove the oil filter.

Tighten them to a torque of 10 Nm (102 kgf-cm, 7 ft-lbf).

Take off the 3 nuts and the gasket from the thermostat.

Add coolant and inspect for any engine coolant leaks.

Remove the nut and clamp to disconnect the engine wire protector from the water inlet and right-hand cylinder head.

Remove the thermostat and install a new one.

Add engine coolant and inspect for any leaks in the engine coolant system.

Place the thermostat in the water pump with a new gasket, aligning the jiggle valve with the upper stud bolt.

Torque the bolt to 20 Nm (204 kgf-cm, 15 ft. lbs.).

Fill with engine coolant, start the engine, check for leaks, and recheck the engine coolant level.

Replace the thermostat.

Reinstall the water inlet with a torque of 11 Nm (112 kgf-cm, 8 ft. lbs.).

Take off the gasket from the thermostat.

Secure the water inlet using 2 nuts, applying a torque of 10 Nm (102 kgf-cm, 7 ft-lbf).

Place the thermostat in the cylinder block with a new gasket and ensure the jiggle valve is positioned upward.

Remove the drive belt and generator.

Next, remove the fan and generator V belt.

Replace the thermostat.

Remove the water inlet by taking off the 2 nuts and then removing the water inlet.

The jiggle valve may be set within 100 degrees on either side of the prescribed position.

Use the 2 nuts and torque them to 10 Nm (100 kgf-cm, 7 ft. lbs.).

Install the engine under cover LH, engine under cover RH, front wheel opening extension pad LH, and front wheel opening extension pad RH.

Ensure the valve is fully closed.

First, drain the coolant.

Remove the drive belt and generator, followed by the front engine under cover.

Take off the 2 nuts.

Reinstall the front engine under cover, generator, and drive belt.

Attach the water inlet using the 2 nuts, applying a torque of 11 Nm (112 kgf-cm, 8 ft-lbf).

Remove the fan and generator V belt and drain the engine coolant.

Reinstall the water inlet, torquing it to 11 Nm (112 kgf-cm, 8 ft. lbs.).

Finally, remove the thermostat and gasket.

The valve opening temperature should be between 80.0 - 84.0°C (176 - 183°F).

Fill with engine coolant, start the engine to check for leaks, and recheck the engine coolant level.

Remove the V-ribbed belt, followed by the generator assembly.

Reinstall the generator and drive belt, fill with engine coolant, start the engine, check for leaks, and recheck the engine coolant level.

First, drain the coolant.

Fill with engine coolant, start the engine to check for leaks, and recheck the engine coolant level.

Install a new thermostat with a gasket, ensuring the jiggle valve is positioned upward, which may be set within 10° on either side of the prescribed position.

Fill the system with engine coolant, start the engine, check for leaks, and recheck the engine coolant level.

Ensure to place a new gasket and position the thermostat with the jiggle valve upward.

Reinstall the radiator hose inlet, generator assembly, and fan and generator V belt.

The valve lift should be 10 mm (0.39 inch) or more at 90°C (194°F).

The jiggle valve should be positioned upward, which may be set within 10° of either side of the prescribed position.

Disconnect the radiator hose outlet and remove the water inlet by disconnecting the wire harness clamp and removing the bolts and 3 nuts.

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

Place the thermostat in the cylinder block with a new gasket and ensure the jiggle valve is positioned upward, allowing for a 10° variance.

Install the generator assembly.

Install a new O-ring on the water inlet pipe, applying soapy water to it before connecting the pipe to the water inlet and securing it with a bolt torqued to 19.5 Nm (200 kgf-cm, 14 ft. lbs.).

Install a new O-ring on the water inlet pipe, applying soapy water before connecting it to the water inlet and securing it with a bolt torqued to 19.5 Nm (200 kgf-cm, 14 ft. lbs.).

Start by placing a new gasket on the thermostat and install it with the jiggle valve facing up, ensuring it is within 10° of the prescribed position.

Reinstall the engine wire protector, connect the ECT switch connectors, and reinstall the air cleaner cap with the air cleaner hose. Fill the system with engine coolant, start the engine, check for leaks, and recheck the engine coolant level.

Place a new gasket onto the thermostat and ensure the jiggle valve is facing upward, positioned within 10° on either side of the prescribed position.

The jiggle valve may be set within 15 degrees of either side of the prescribed position.

Remove the air cleaner cap along with the air cleaner hose.

Remove the thermostat and install a new one with a gasket, ensuring the jiggle valve is facing up.