WATER PUMP INSTALLATION

INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 2 TIMING BELT COVER
1. Apply seal packing (FIPG) to the specified areas shown in the illustration.
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Note
  
  After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.
2. Install the No. 2 timing belt cover with the 4 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CAMSHAFT TIMING PULLEY
1. Install the camshaft timing pulley.
2. Fasten the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
  
  Torque:
  
  98 N*m { 1000 kgf*cm, 72 ft.*lbf }
INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
1. Using a 10 mm hexagon wrench, install a new washer and the timing belt idler pulley with the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Do not reuse the washer.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover as shown in the illustration.
  Note
  
  Do not install the gaskets at an angle.
  
  Keep the lip of the gasket free from foreign materials.
2. Install a new cylinder head cover gasket to the cylinder head cover.
3. Apply a seal packing to the cylinder head as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any old packing from the contact surface.
  
  After applying the seal packing, install the cylinder head cover within 3 minutes, and tighten the bolts within 15 minutes.
4. Install the cylinder head cover with the 10 bolts and 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
5. Connect the ventilation hose.
6. Install new nozzle holder seals.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
Note
- When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe.
- Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.
1. Temporarily install the fuel inlet pipe.
2. Connect the No. 1 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
4. Using SST, tighten the union nut on the common rail side.
  
  SST
  
  09023-12701
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with SST }
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without SST }
  Tech Tips
  - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
  - This torque value is effective when SST is parallel to a torque wrench.
5. Using SST, tighten the union nut on the supply pump side.
  
  SST
  
  09023-12701
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with SST }
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without SST }
  Tech Tips
  - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
  - This torque value is effective when SST is parallel to a torque wrench.
INSTALL INJECTION PIPE
Note
- When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.
- Keep the injection pipe connection clean.
1. Install the injection pipes.
  1. Temporarily install the 4 injection pipes.
  2. Install the 2 No. 2 injection pipe clamps with the 2 bolts.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  3. Using SST, tighten the union nut on the fuel injector side to the specified torque.
    
    SST
    
    09023-12701
    
    Torque:
    
    32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with SST }
    
    35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without SST }
    
    Tech Tips
    
    Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
    
    This torque value is effective when SST is parallel to a torque wrench.
  4. Using SST, tighten the union nut on the common rail side to the specified torque.
    
    SST
    
    09023-12701
    
    Torque:
    
    32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with SST }
    
    35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without SST }
    
    Tech Tips
    
    Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
    
    This torque value is effective when SST is parallel to a torque wrench.
  5. Install the 3 bolts.
  6. Connect the fuel injector connector and harness clamps.
INSTALL OIL LEVEL GAUGE GUIDE
1. Install a new O-ring to the oil level gauge guide.
2. Apply a light coat of engine oil to the O-ring.
3. Install the oil level gauge guide with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
4. Install the oil level gauge.
INSTALL TIMING BELT
1. Check that the timing marks are aligned as shown in the illustration.
  
  Tech Tips
  
  If reusing the timing belt, align the matchmarks marked during removal, and install the belt with the direction arrow pointing in the direction of engine revolution.
  Note
  
  The engine should be cold.
  
  When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.
2. Install the timing belt to pump drive shaft pulley, camshaft timing pulley and No.1 timing belt idler in sequence.
3. Place the tensioner upright into a press. Then set the press to the top of tensioner.
  Note
  
  Do not scratch and deform the rod end.
  
  Press the tensioner rod in upward.
  
  Protect the tip of the push rod with a shop rag or piece of cloth in order to prevent damage.
4. Using the press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.
  
  Note
  
  Do not apply a load of 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) or more to the push rod.
5. Align the holes of the push rod and housing and pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.
7. Tighten the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Note
  
  Uniformly tighten the 2 bolts when installing the tensioner
8. Remove the 1.27 mm hexagon wrench from the tensioner.
9. Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.
INSTALL NO. 1 TIMING BELT COVER
1. Install the No.1 timing belt cover with the 6 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
2. Install the wire harness clamp.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner with the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
1. Install the generator with the bolt.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
2. Install the generator wire to terminal B with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 7.2 ft.*lbf }
3. Install the terminal cap.
4. Connect the generator connector.
INSTALL GENERATOR BRACKET
1. Install the generator bracket with the 2 bolts.
  
  Torque:
  
  36 N*m { 367 kgf*cm, 27 ft.*lbf }
INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)
1. Install the No.2 idle pulley assembly and washer with the bolt.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the compressor bracket with the 4 bolts.
  
  Tech Tips
  
  Make sure that the compressor bracket is in contact with the engine block.
2. Tighten the 4 bolts in the sequence shown in the illustration.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL COMPRESSOR OUTLET ELBOW
1. Install the compressor outlet elbow with the 2 hose clamps and bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL AIR TUBE ASSEMBLY
1. Install the air tube assembly with the 2 hose clamps and 2 bolts.
  
  Torque:
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf, for bolt A }
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf, for bolt B }
INSTALL NO. 1 AIR CLEANER HOSE
1. Install the air cleaner hose to the compressor inlet elbow.
  
  Note
  
  Pull the hose to make sure that it is locked and securely connected.
INSTALL W/ PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Install the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
TEMPORARILY TIGHTEN FAN PULLEY
1. Temporarily install the fan pulley with the 4 nuts.
INSTALL FAN & GENERATOR V BELT
1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.
  
  Note
  
  Make sure that the fan and generator V belt is set properly on each pulley.
2. Check that the indicator mark of the V-ribbed belt tensioner Click here.
TIGHTEN FAN PULLEY
1. Tighten the 4 nuts and install the fan pulley.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
1. Install the vane pump oil reservoir assembly with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL RADIATOR HOSE INLET
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:

5.4 N*m { 55 kgf*cm, 48 in.*lbf }
BLEED AIR FUEL LINE
1. Using a hand pump, bleed air from the fuel system until pumping becomes difficult.

Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

ADD ENGINE COOLANT

Firmly tighten the drain plugs.

Fill the radiator reserve tank assembly with coolant to the top of the inlet.

Coolant capacity

Condition	Capacity
w/ rear heater	18.2 liters (19.2 US qts, 16.0 lmp. qts)
w/o rear heater	16.2 liters (17.0 US qts, 14.0 lmp. qts)

Note

Do not substitute plain water for engine coolant.

Tech Tips

Use of improper coolants may damage the engine cooling system.
Use only 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 (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

Loosen the bleeder plug of the outlet housing.
When air is bled and the coolant drains out, firmly install the bleeder plug.
Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.
Warm up the engine until the thermostat opens.
1. While the thermostat is open, circulate the coolant for several minutes.
  
  Tech Tips
  
  The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

INSPECT FOR COOLANT LEAK

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 19.9 psi), and check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSPECT FOR FUEL LEAK
INSTALL FENDER APRON MUDGUARD SEAL RH
INSTALL NO. 2 ENGINE SERVICE HOLE COVER
1. Install the No. 2 engine service hole cover with the 3 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Return the carpet.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the engine service hole sub cover sub-assembly with the 5 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT SEAT ASSEMBLY RH
1. Connect the front seat inner belt assembly connector and install the front seat assembly.
2. Align the front seat assembly adjuster pin with the holes in the body.
3. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.
5. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.
7. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
9. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH