WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A0137SSE02

      Install and uniformly tighten the 5 bolts, water pump assembly and the water pump gasket in the sequence shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  2. INSTALL WATER PUMP PULLEY


    1. A013638E02

      Using SST, install the water pump pulley with the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  3. INSTALL GENERATOR ASSEMBLY


    1. A0138RAE01

      Install the generator with the 2 bolts.

      Torque:
      Bolt (A)
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
      Bolt (B)
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
    2. A013629E02

      Install the wire harness clamp with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    3. Install the generator wire with the nut to the terminal D.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

    4. Install the generator wire with the nut to the terminal B.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    5. Install the terminal cap.

  4. CONNECT COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning)

    A013767E01

    1. Provisionally tighten the compressor and magnetic clutch with the 3 bolts.

    2. Provisionally tighten compressor stay No. 1 with the bolt and nut.

    3. Tighten the compressor and magnetic clutch with the 4 bolts and nut.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the sequence order shown in the illustration to install the compressor and magnetic clutch.

    4. Connect the connector.

  5. INSTALL FAN AND GENERATOR V BELT


    1. Install the fan and generator V belt Click here.

  6. ADD ENGINE COOLANT


    1. Connect the engine side radiator outlet hose .

    2. A0137DX

      Install the cylinder block drain cock plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Pour engine coolant into the radiator assembly until it is full.

      Capacity
      Specification Capacity
      except Tropic Spec 4.0 liters (4.2 US qts, 3.5 Imp qts)
      for Tropic Spec 4.4 liters (4.6 US qts, 3.9 Imp qts)

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant 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 engine 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).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. Install the radiator cap sub-assembly securely.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. The thermostat open timing can be confirmed by pressing the outlet radiator hose by hand, and checking when the coolant starts to flow inside the hose.

      3. Maintain the engine speed at 2500 to 3000 rpm and warm up the engine until the cooling fan operates.

      4. Press the outlet radiator hose and inlet radiator hose several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. Stop the engine and wait until the coolant cools down.

    9. If the engine coolant level is below the full level, perform steps (c) through (h) and repeat the operation until the engine coolant level stays the full level.

    10. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.

  7. INSPECT FOR ENGINE COOLANT LEAKS

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375K

      Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

    2. Warm up the engine.

    3. Pump it to 137 kpa (1.4 kgf*cm2, 19.9 psi), then check that the pressure does not drop.


      • If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.

    4. Be sure not to put more than 177 kpa (1.8 kgf*cm2, 25.6 psi).

  8. INSTALL FRONT BUMPER COVER

    A0136YZ

    1. Install the 2 clips.

    2. A01360O

      Engage the 13 claws and install the front bumper cover.

    3. A013716E01

      Tighten the 3 bolts and 5 screws.

    4. Install the 3 clips.

    5. Remove the protective tape.