WATER PUMP INSTALLATION

INSTALL ENGINE WATER PUMP ASSEMBLY
1. Install a new gasket and the engine water pump assembly together with the water pump pulley with the 16 bolts.
  
  Torque:
  
  Bolt A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Bolt B and C
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
  Note
  
  Make sure that there is no oil on the threads of bolts A.
  
  Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344.
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

INSTALL WATER PUMP PULLEY

Temporarily install the water pump pulley with the 4 bolts.

Text in Illustration
*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

Using SST, hold the water pump pulley.

SST: 09960-10010 ( 09962-01000, 09963-00700 )

Using SST and union nut wrench, tighten the 4 bolts.

SST

09961-00950

Torque:

Specified tightening torque

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Tech Tips
- Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
- When using SST (fulcrum length of 170 mm (6.69 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 11 N*m (112 kgf*cm, 8 ft.*lbf)

INSTALL WATER INLET HOUSING
1. Install 2 new O-rings.
2. Install the water inlet housing with the 2 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Be careful not to allow the O-ring to get caught between the parts.
3. Connect the water hose.

INSTALL V-RIBBED BELT TENSIONER PULLEY

Text in Illustration
*1	Dust Shield
*2	Pulley
*a	Correct
*b	Incorrect

Install the V-ribbed belt tensioner pulley and dust shield with the bolt.

Note

Be careful when tightening the bolt because its thread is left-handed.
Install the dust shield in the direction shown in the illustration. Failure to do so may cause looseness.
Make sure to use the removed bolt. (Do not use another bolt even if it is the same size.)

Torque:: 48 N*m { 489 kgf*cm, 35 ft.*lbf }

Install the 5 mm bi-hexagon wrench.

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
  
  Torque:
  
  54 N*m { 550 kgf*cm, 40 ft.*lbf }
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
1. Temporarily install the front No. 1 engine mounting bracket LH with the 6 bolts.
2. Fully tighten the 5 bolts.
  
  Torque:
  
  54 N*m { 551 kgf*cm, 40 ft.*lbf }
3. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using SST, fully tighten the bolt.
  
  SST
  
  09961-00950
  
  Torque:
  
  Specified tightening torque
  
  54 N*m { 551 kgf*cm, 40 ft.*lbf }
  Tech Tips
  
  Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  
  When using SST (fulcrum length of 150 mm (5.905 in.)) + torque wrench (fulcrum length of 260 mm (10.23 in.)): 34 N*m (347 kgf*cm, 25 ft.*lbf)
INSTALL ENGINE MOVING CONTROL ROD BRACKET
1. When replacing the engine moving control rod.
  1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.
    
    Torque:
    
    38 N*m { 387 kgf*cm, 28 ft.*lbf }
    
    Note
    
    Temporarily tighten bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).
  2. Install the bolt (E).
    
    Torque:
    
    52 N*m { 530 kgf*cm, 38 ft.*lbf }
2. When not replacing the engine moving control rod.
  1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.
    
    Torque:
    
    38 N*m { 387 kgf*cm, 28 ft.*lbf }
    
    Note
    
    Temporarily tighten bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).
INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side)
1. Install the No. 2 engine mounting stay RH with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side)
1. Install the No. 2 engine mounting stay RH with the bolt.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
2. Install the 2 nuts.
  
  Torque:
  
  23 N*m { 234 kgf*cm, 17 ft.*lbf }
CONNECT OUTLET RADIATOR HOSE
1. Connect the outlet radiator hose and slide the clip to secure it.
INSTALL V-RIBBED BELT

Click here
ADD ENGINE COOLANT
1. Tighten the radiator drain cock plug by hand.
2. Close the 2 cylinder block drain cock plugs.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
3. Loosen the air drain cock plug on the water inlet housing.
4. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
5. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).
  
  Specified capacity
  
  9.1 liters (9.6 US qts, 8.0 lmp. qts)
  
  Tech Tips
  
  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).
6. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line.
7. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
  
  If the coolant level is low, add coolant.
8. Install the radiator cap sub-assembly and reserve tank cap.
9. Bleed air from the cooling system.
  Note
  - Before starting the engine, turn the A/C switch off.
  - Adjust the heater control to the maximum hot setting.
  - Adjust the blower speed to the low setting.
  1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
    
    Tech Tips
    
    The thermostat open timing can be confirmed by squeezing the outlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.
  2. Maintain the engine speed at 2500 to 3000 rpm.
  3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.
    CAUTION:
    
    When squeezing the radiator hoses:
    - Wear protective gloves.
    - Be careful as the radiator hoses are hot.
    - Keep your hands away from the radiator fans.
    Note
    - Make sure that the radiator reserve tank assembly still has some coolant in it.
    - If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
    - If there is not enough coolant, the engine may overheat or be seriously damaged.
    - If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.
10. Stop the engine, and wait until the engine coolant cools down.
11. Add engine coolant to the full line on the radiator reserve tank assembly.
INSPECT FOR COOLANT LEAK
CAUTION:

Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Note

Before performing each inspection, turn the A/C switch OFF.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
  
  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.