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Toyota Chassis and Body workshop and repair manual

Tools & supplies
- Safety: chemical-resistant gloves, safety glasses, shop rags, drain pan (large), funnels.
- Basic hand tools: ratchet & sockets, screwdrivers, pliers, hose clamp pliers, catch tray.
- Drain/flush tools: radiator petcock wrench or pliers (if different), garden-hose-to-radiator-adapter flush kit or dedicated radiator flush gun, adjustable hose adapter or lower-hose quick-connect for backflush.
- Filling/bleeding: coolant funnel / spill-free funnel, 50/50 premixed Toyota-recommended coolant or concentrate + distilled water.
- Optional but recommended: new thermostat, new radiator cap, new lower/upper radiator hose(s) if cracked, new clamps, replacement drain plug washer.
- Consumables: shop towels, container for old coolant (sealed jug), degreaser for spills.
- Disposal: container to transport used coolant to hazardous-waste site.

Safety precautions (don’t skip)
- Do NOT open the radiator cap while the engine is hot — scald risk. Let engine cool completely (at least 1–2 hours after running).
- Work on a level surface; use jack stands if raising vehicle. Chock wheels.
- Keep coolant away from children/pets — ethylene glycol tastes sweet and is toxic.
- Wear gloves and eye protection; avoid skin contact and ingestion.
- Collect and dispose of used coolant per local regulations.

Step-by-step coolant flush (typical Toyota)
1) Warm engine, then cool
- Start and run engine until normal operating temp reached so thermostat has cycled (5–10 minutes). Turn off and allow to cool until safe to touch radiator cap/surfaces.

2) Position and prepare
- Park level, set parking brake, chock wheels. Place drain pan under radiator drain petcock or lower radiator hose connection. Remove engine cover if it impedes access.

3) Remove radiator cap (only when cool)
- Remove radiator cap or coolant reservoir cap once the engine is cool to allow faster draining/venting.

4) Drain old coolant
- Open the radiator drain petcock (usually lower passenger side of radiator) or loosen lower radiator hose clamp and remove lower hose to drain. Also open engine block drain if accessible to get more out (not present on all models). Remove coolant reservoir cap and any bleeder screw near thermostat housing if equipped.
- Let coolant fully drain to pan. Tighten petcock or reattach lower hose when draining is complete.

5) (Optional but recommended for thorough flush) Remove thermostat
- Remove thermostat housing (note orientation) and take thermostat out. This allows a more complete flush and prevents the thermostat from blocking flow during backflush. Replace thermostat with new if age >4–5 years or suspect. Keep gasket/ O-ring replacement.

6) Backflush radiator
- Attach garden-hose flush adapter to lower radiator outlet or to the radiator core inlet after removing lower hose. With the upper radiator cap open and the thermostat removed (if removed), run water through the radiator until the outgoing water runs clear, or use a flush chemical per instructions:
- How tool is used: connect hose adapter to lower radiator outlet, open adapter valve fully to allow water to flow in reverse through radiator and out the top through the neck or overflow. Use towel to catch splashes. If using a dedicated flush gun or pressure-flush kit, follow manufacturer instructions; typical use is to pressurize water flow into core, agitate, then flush until clear.
- Backflush both directions if needed (alternately feed water from bottom then from top) to remove deposits and sediment. Continue until water is clear and free of debris.

7) Flush engine block (coolant passages)
- With thermostat removed, run clean water through the block via the lower hose and let it drain until clear water appears. You can also run the engine briefly with fresh coolant to purge air later, but don’t run it long without a thermostat and proper coolant concentration.

8) Reinstall thermostat & secure drains
- Install new thermostat (if replacing) with correct orientation and new gasket/seal. Tighten housing bolts to specified torque if known; snug is fine but don’t over-torque plastic housings.
- Reattach lower hose and tighten clamps; close drain petcock. Replace drain plug washer if applicable.

9) Fill with correct coolant
- Pre-mix 50/50 coolant/water or use manufacturer premix. Pour into radiator (or use funnel at radiator neck) until full, then fill overflow reservoir to the appropriate level. Use Toyota-recommended coolant type (check owner’s manual — many Toyotas use long-life OAT/“pink” coolant).

10) Bleed trapped air
- Start engine with heater on max and A/C off. Allow engine to idle and come to normal temp so thermostat opens. Watch for bubbles/foaming in radiator neck or use a spill-free funnel to capture air. Some Toyotas have a specific bleeder screw near the thermostat housing — open slightly to release air until steady coolant emerges, then close.
- Squeeze upper radiator hose several times to help expel trapped air. Top up radiator and reservoir as air is purged.
- Continue until no more air bubbles appear and coolant level stabilizes.

11) Run and check
- With engine at operating temp, check for leaks around thermostat housing, hoses, clamps, petcock. Cycle heater to confirm hot air. Shut off and let cool, then re-check level and top up as needed.

12) Final checks & disposal
- Reinstall radiator cap, engine cover, clean spills. Label and store old coolant securely and take to hazardous waste disposal or recycling center — never pour down drains or onto ground.

Common pitfalls & how to avoid them
- Opening hot radiator cap: always wait until cool to avoid severe burns.
- Not bleeding air: trapped air causes overheating/hot spots. Use bleeder screw and heater at max to purge air.
- Mixing incompatible coolants: don’t mix colors/types (OAT vs IAT/Dex-Cool). Use Toyota-recommended coolant.
- Not replacing old thermostat or cap: a failing thermostat or cap can cause overheating/pressure loss; replace if old.
- Overfilling: leave correct headspace and fill to specified reservoir marks.
- Inadequate flushing: stopping before clear water leads to leftover deposits—flush until water runs clear.
- Spills and pets: store/clean coolant immediately—pets will ingest sweet coolant.

Replacement parts commonly required
- Coolant (volume per vehicle — check owner’s manual).
- Thermostat and gasket (highly recommended).
- Radiator cap.
- Hose clamps or new radiator hoses if cracked.
- Drain-petcock washer or plug gasket.

Notes on coolant selection
- Use the Toyota factory coolant type specified in the service manual (many later Toyotas use pink/orange long-life ethylene glycol OAT). If uncertain, use a high-quality 50/50 premix of ethylene glycol coolant compatible with Toyota systems.

This procedure is a general guide — always follow vehicle-specific service manual specs and torque values where available. Dispose used coolant responsibly.
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