WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A015E4WE01

      Install a new gasket and the water pump with the 8 bolts shown in the illustration.

      Torque:
      for bolt A
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
      for bolt B
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      for bolt C
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length Thread Diameter
      Bolt A 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt B 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt C 25 mm (0.984 in.) 8 mm (0.315 in.)

  2. INSTALL WATER PUMP PULLEY


    1. Temporarily install the pulley with the 4 bolts.

    2. A015BB7E02

      Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  3. INSTALL WATER INLET HOUSING


    1. Install a new gasket to the water pump.

    2. A0157ABE04
      Text in Illustration
      *1 No. 3 Water By-pass Hose
      *a RH Side
      *b Front

      Install the water inlet housing with the 3 bolts and connect the No. 3 water by-pass hose.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Install the hose so that the direction of the hose clamp is as indicated in the illustration.

    3. A0158XQE01
      Text in Illustration
      *a RH Side
      *b Front

      Connect the No. 5 water by-pass hose.

      Tech Tips

      Install the hose so that the direction of the hose clamp is as indicated in the illustration.

  4. CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    A0158VGE03
    Text in Illustration
    *a Upper
    *b Front

    1. Connect the water by-pass pipe with water hose.

      Tech Tips

      Install the hose so that the direction of the hose clamp is as indicated in the illustration.

    2. Install the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 6 water by-pass hose.

  5. INSTALL NO. 1 WATER BY-PASS HOSE


    1. Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

  6. INSTALL FAN SHROUD


    1. Install the fan pulley.

    2. Place the shroud together with the coupling fan between the radiator and engine.

      Note

      Be careful not to damage the radiator core.

    3. Temporarily install the fluid coupling fan to the fluid coupling bracket with the 4 nuts. Tighten the nuts as much as possible by hand.

    4. A015BAR

      Attach the claws of the shroud to the radiator as shown in the illustration.

    5. Install the shroud with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Connect the oil cooler tube to the fan shroud with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    7. Pass the hose through the flexible hose clamp and close the clamp as shown in the illustration.

    8. Connect the reservoir hose to the upper radiator tank.

    9. Install the fan and generator V-belt Click here.

    10. Tighten the 4 nuts of the fluid coupling fan.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  7. INSTALL NO. 1 RADIATOR HOSE

  8. INSTALL NO. 2 RADIATOR HOSE

  9. INSTALL AIR CLEANER ASSEMBLY


    1. Install the air cleaner with the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  10. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. A015CFTE01
      Text in Illustration
      *1 Groove
      *2 Protrusion

      Install the air cleaner hose so that the protrusion of the air cleaner cap aligns with the groove of the hose as shown in the illustration.

    2. Tighten the 2 clamps.

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

    3. Connect the vacuum hose.

    4. Connect the No. 2 ventilation hose.

  11. ADD ENGINE COOLANT


    1. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      with rear heater 16.2 liters (17.1 US qts, 14.3 Imp. qts)
      without rear heater 13.4 liters (14.2 US qts, 11.8 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      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 consists of a combination of low phosphates and organic acids).

    2. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    3. Install the reservoir cap.

    4. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    5. Install the radiator cap.

    6. Start the engine and warm it up until the thermostat opens.

      Tech Tips

      The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. Maintain the engine speed at 2000 to 2500 rpm.

      Note


      • Make sure that the radiator reservoir still has some coolant in it.

      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Run the engine at 2000 rpm until the coolant level has stabilized.

    8. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    9. Stop the engine, and wait until the engine coolant cools down to ambient temperature.

      CAUTION:

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

    10. Check that the coolant level is between the F and L lines.

      If the coolant level is below the L line, repeat all of the procedures above.

      If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

  12. INSPECT FOR COOLANT LEAK

    A0156I2

    CAUTION:

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


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 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 head.

  13. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A0157E7E02
      Text in Illustration
      *1 Bracket
      *2 Hook
      *3 Pin
      *4 Grommet

      Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

  14. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 10 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  15. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Push in the clip to install the front fender splash shield sub-assembly LH.

    2. Install the 3 bolts and screw.

  16. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Push in the clip to install the front fender splash shield sub-assembly RH.

    2. Install the 3 bolts and 2 screws.