WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. Install a new gasket, the water pump and tension spring bracket with the 6 bolts.

      Torque:
      23 N*m  { 230 kgf*cm, 17 ft.*lbf }

  2. INSTALL TIMING BELT

    SST
    09960-10010   ( 09962-01000, 09963-01000 )

  3. SET NO.1 CYLINDER TO TDC/COMPRESSION


    1. A01BGVME01

      Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.

      Note

      Do not turn the crankshaft pulley counterclockwise.

    2. A01BEAHE01

      Set the timing and drive pulleys at each position.

      Note


      • The engine should be cold.

      • When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.

  4. INSTALL TIMING BELT GUIDE


    1. A01BE7XE01

      Install the belt guide with the cup side facing outward.

  5. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Remove the 2 nuts and wire harness clamp bracket.

    2. A01BH7DE01

      Install the 2 gaskets to the timing belt cover.

    3. A01BFU5

      Install the timing belt cover with the 11 bolts.

      Torque:
      11 N*m  { 105 kgf*cm, 8 ft.*lbf }

    4. Install the 2 nuts and wire harness clamp bracket.

  6. INSTALL CRANKSHAFT PULLEY

    SST
    09213-54015   ( 91651-60855 )
    09330-00021

  7. INSTALL VANE PUMP PULLEY


    1. A01BCC2E01

      Using SST, install the vane pump pulley to the vane pump assembly.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

  8. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. Temporarily install the compressor mounting bracket with the 4 bolts.

    2. A01BFW5E01

      Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01BDNC

      Temporarily tighten the bolt and spacer.

    4. A01BDQDE01

      Temporarily install the compressor mounting bracket with the 3 bolts.

    5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      47 N*m  { 475 kgf*cm, 36 ft.*lbf }

  9. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. A01BGZOE01

      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.

  10. INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A01BBR9E01

      Install the V belt.

    2. Using a bar, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  11. INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning System)


    1. A01BAGHE01

      Install the V belt.

    2. Tightening the bolt C, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  12. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1


    1. A01BEBYE01

      Install the V belt.

    2. Tightening the bolt B, adjust the tension of the V belt.

    3. Tighten nut A.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    4. Check the tension of the V belt. Click here

  13. INSTALL VANE PUMP V BELT (w/ Air Conditioning System)


    1. A01BCBTE01

      Install the V belt.

    2. Using a bar, adjust the tension of the V-ribbed belt.

    3. Tighten the bolt A and nut B.

      Torque:
      Bolt (A)
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
      Nut (B)
      64 N*m  { 635 kgf*cm, 47 ft.*lbf }

    4. Check the tension of the V belt. Click here

  14. INSTALL WATER PUMP PULLEY

  15. CONNECT RADIATOR HOSE NO.4

  16. CONNECT RADIATOR HOSE INLET

  17. ADD ENGINE COOLANT


    1. Fill the radiator reservoir assembly with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Front Heater 13.3 liters (14.1 US qts, 11.7 Imp. qts)
      w/ Front and Rear Heaters 15.3 liters (16.2 US qts, 13.5 Imp. 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).

    2. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir assembly and install the reservoir cap.

    3. 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.

    4. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  18. START THE ENGINE

  19. CHECK FOR ENGINE COOLANT LEAKS

  20. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the 5 bolts and engine service hole cover.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  21. INSTALL FRONT DOOR SCUFF PLATE RH

  22. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      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 }