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Print-Toyota Service Information 11/3/17, 6(33 pm Print Exit 1GD-FTV COOLING COOLANT REPLACEMENT CAUTION / NOTICE / HINT CAUTION: · · Do not remove the radiator reservoir cap sub-assembly, vent plug, 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 To prevent injury due to contact with an operating fan and generator V-belt or cooling fan, keep your hands and clothing away from the fan and generator V-belt and cooling fans when working in the engine compartment with the engine running PROCEDURE https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8C.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(33 pm 12601B 1.REMOVE NO ENGINE COVER SUB-ASSEMBLY Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>REMOVAL 2.DRAIN ENGINE COOLANT CAUTION: Do not remove the radiator reservoir cap sub-assembly, vent plug, 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 *a HOSE Connect a hose with an inside diameter of mm (0.354 in.) to the radiator drain cock as shown in the illustration b Loosen the radiator drain cock plug *1 *3 Radiator Reservoir Vent Plug *2 *4 Radiator Reservoir Cap Sub-Assembly Cylinder Block Drain Cock Plug https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8C.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information *5 Radiator Drain Cock Plug 11/3/17, 6(33 pm - - HINT: Collect the engine coolant in a container and dispose of it according to the regulations in your area c Using a wrench, remove the vent plug and radiator reservoir cap sub-assembly, and then drain the engine coolant d Loosen the cylinder block drain cock plug e Slide the hose clamp and remove the vent plug, and then drain the engine coolant from the water by-pass pipe assembly f Tighten the cylinder block drain cock plug Torque: 12.7 N*m (130 kgf*cm, ft.*lbf) g Tighten the radiator drain cock plug by hand and remove the hose from the radiator drain cock 3.ADD ENGINE COOLANT CAUTION: · · Do not remove the radiator reservoir cap sub-assembly, vent plug, 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 To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your hands and clothing away from the fan and generator V belt and the fan when working in the engine compartment with the engine running or the ignition switch to ON https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8C.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(33 pm a Add engine coolant to the radiator reservoir filler opening until it is filled to the B line at the base of the radiator reservoir filler neck Standard Capacity: Item Specified Condition for Manual Transmission w/o DPF 8.6 liters (9.1 US qts, 7.6 Imp qts) w/ DPF 8.7 liters (9.2 US qts, 7.7 Imp qts) w/o DPF 9.1 liters (9.6 US qts, 8.0 Imp qts) w/ DPF 9.2 liters (9.7 US qts, 8.1 Imp qts) w/ DPF 9.6 liters (10.1 US qts, 8.4 Imp qts) w/o Viscous Heater for Automatic Transmission w/ Viscous Heater for Automatic Transmission NOTICE: Do not substitute plain water for engine coolant HINT: · · TOYOTA vehicles are filled with TOYOTA SLLC at the factory In order to avoid damage to 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) The B line is the lower edge of the inner wall of the filler neck b Press the No radiator hose and No radiator hose several times by hand, and then check the level of the engine coolant If the coolant level drops below the B line, add engine coolant to the B line c Install the radiator reservoir cap sub-assembly d https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8C.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information *1 Vent Plug *2 Hose Clamp *a 1.0 to 3.0 mm (0.0394 to 0.118 in.) 11/3/17, 6(33 pm Install the vent plug to the water by-pass pipe assembly and slide the hose clamp to secure the plug NOTICE: Make sure the hose clamp is securely installed at the location shown in the illustration Otherwise, coolant may leak e Using a wrench, install the vent plug Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) f Bleed air from the cooling system i Warm up the engine until the thermostat opens While the thermostat is open, circulate the engine coolant for several minutes ii iii Maintain the engine speed at 2500 to 3000 rpm Press the No radiator hose and No radiator hose several times by hand to bleed air CAUTION: · · · iv g Wear protective gloves Be careful as the radiator hoses are hot Keep your hands away from the radiator fan Stop the engine and wait until the engine coolant cools down to ambient temperature After the engine coolant cools down, check that the coolant level is at the F line If the coolant level is below the F line, add engine coolant to the F line 4.INSPECT FOR COOLANT LEAK Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION 5.INSTALL NO ENGINE COVER SUB-ASSEMBLY 12601B Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>INSTALLATION © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8C.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(33 pm Print Exit 1GD-FTV COOLING COOLING SYSTEM ON-VEHICLE INSPECTION CAUTION / NOTICE / HINT CAUTION: Do not remove the radiator reservoir cap sub-assembly while the engine and radiator assembly are still hot Pressurized, hot engine coolant and steam may be released and cause serious burns PROCEDURE 1.INSPECT FOR COOLANT LEAK CAUTION: Do not remove the radiator reservoir cap sub-assembly while the engine and radiator assembly are still hot Pressurized, hot engine coolant and steam may be released and cause serious burns NOTICE: Before each inspection, turn the A/C switch off a Remove the radiator reservoir cap sub-assembly b Fill the radiator assembly with engine coolant and attach a radiator cap tester c Warm up the engine d Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MV8A.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(33 pm If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly e Remove the radiator cap tester and install the radiator reservoir cap sub-assembly 2.INSPECT ENGINE COOLANT LEVEL ON RESERVOIR a Check that the engine coolant level is between the L and F lines when the engine is cold If the engine coolant level is low, check for leaks and add TOYOTA Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology up to the F line NOTICE: Do not substitute plain water for engine coolant 3.INSPECT ENGINE COOLANT QUALITY CAUTION: Do not remove the radiator reservoir cap sub-assembly 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 radiator reservoir cap sub-assembly b Check for any excessive deposits of rust or scale around the radiator reservoir cap sub-assembly and check that the engine coolant is free of oil If the engine coolant is excessively dirty, replace the engine coolant c Install the radiator reservoir cap sub-assembly © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8A.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(33 pm Print Exit 1GD-FTV COOLING COOLING SYSTEM PRECAUTION IGNITION SWITCH EXPRESSIONS a The type of ignition switch used on this model differs depending on the specifications of the vehicle The expressions listed in the table below are used in this section Ignition Switch Engine Switch Expression (Position) (Condition) Ignition Switch off LOCK Off (Lock) Ignition Switch ACC ACC On (ACC) Ignition Switch ON ON On (IG) Engine Start START On (Start) © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MV8B.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(36 pm Print Exit 1GD-FTV COOLING RADIATOR COMPONENTS ILLUSTRATION *A for 4WD and Pre-Runner *1 *3 NO ENGINE COVER SUB-ASSEMBLY NO OIL RESERVOIR BRACKET *2 *4 NO ENGINE UNDER COVER ASSEMBLY NO RADIATOR AIR GUIDE *5 NO AIR TUBE *6 NO AIR HOSE *7 RADIATOR RESERVOIR *8 VANE PUMP OIL RESERVOIR ASSEMBLY *9 RADIATOR RESERVOIR CAP SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf): Specified torque - - *10 OIL RETURN HOSE ● Non-reusable part ILLUSTRATION https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8M.html?PUB_TYPE=RM&MODE=1 Page of Print-Toyota Service Information 11/3/17, 6(36 pm *A w/ Viscous Heater *B for Automatic Transmission *C *1 w/o Air Conditioning System FAN SHROUD *2 NO OIL COOLER INLET HOSE *3 *5 NO OIL COOLER OUTLET HOSE NO RADIATOR HOSE *4 *6 NO RADIATOR HOSE RADIATOR ASSEMBLY *7 *9 RADIATOR DRAIN COCK PLUG VISCOUS HEATER V BELT *8 *10 RADIATOR PROTECTOR FAN AND GENERATOR V BELT *11 FAN WITH FLUID COUPLING ASSEMBLY *12 FAN PULLEY *13 O-RING - N*m (kgf*cm, ft.*lbf): Specified torque ● - Non-reusable part © 2012 TOYOTA MOTOR CORPORATION All Rights Reserved https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MV8M.html?PUB_TYPE=RM&MODE=1 Page of