WATER PUMP INSTALLATION

INSTALL GENERATOR ASSEMBLY

1. 

   Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

2. 

   Install the generator assembly with the 2 bolts.

   Bolt A
   52 N*m	530 kgf*cm	38 ft.*lbf
   Bolt B
   21 N*m	214 kgf*cm	15 ft.*lbf

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

   9.8 N*m

   100 kgf*cm

   88 in.*lbf

4. Install the clamp bracket with the bolt.

   7.7 N*m

   79 kgf*cm

   68 in.*lbf

5. Attach the clamp and connect the generator connector to the generator.

INSTALL RADIATOR RESERVE TANK BRACKET

1. Install the radiator reserve tank bracket with the 2 bolts.

   12 N*m

   122 kgf*cm

   9 ft.*lbf

INSTALL RADIATOR RESERVE TANK ASSEMBLY

1. Install the radiator reserve tank assembly to the radiator reserve tank bracket.

   12 N*m

   122 kgf*cm

   9 ft.*lbf

2. Connect the No. 1 and No. 2 water by-pass hoses.

3. Connect the wire harness clamp to the radiator reserve tank assembly.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Add engine coolant.

   Standard capacity
   8.6 liters (9.1 US qts, 7.6 Imp. qts)

   Note:

   Do not substitute plain water for engine coolant.

   Tip:
   

   • 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).

   • Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

     If the engine coolant level is low, add engine coolant.

3. 

   Continue adding engine coolant until it reaches the B line. (*1)

   Table 5. Text in Illustration

   *a

   B Line

4. Install the reserve tank cap. (*2)

5. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes. (*3)

   CAUTION:
   
   

   • Wear protective gloves.

   • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

   • Keep your hands away from the fan and No. 2 fan.

   Note:
   

   • If the radiator reserve tank runs out of engine coolant just after the engine is started, stop the engine immediately, wait until the engine coolant has cooled down, and then add engine coolant.

   • Make sure that the radiator reserve tank still has some engine 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 engine coolant, the engine may overheat or be seriously damaged.

   Tip:
   

   • 

     If engine coolant comes out from the port connected to the radiator reserve tank, the thermostat has been opened.

     Table 6. Text in Illustration

     *a

     Port

   • After the thermostat has opened, idle the engine until the engine coolant in the radiator reserve tank goes from being cloudy to a clear red.

6. Stop the engine and wait until the engine coolant cools down. (*4)

7. 

   Check that the engine coolant level is between the full line and low line. (*5)

   Table 7. Text in Illustration

   *a	Full Line
   *b	Low Line

   Tip:
   

   • If the engine coolant level is below the low line, remove the reserve tank cap and repeat steps from (*1) to (*5).

   • If the engine coolant level is above the full line, drain engine coolant so that the engine coolant level is between the full line and low line.

INSPECT FOR COOLANT LEAK

1. Remove the reserve tank cap.

   CAUTION:

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

2. 

   Fill the radiator and radiator reserve tank with coolant, and then attach a radiator cap tester.

   Table 8. Text in Illustration

   *1	Radiator Cap Tester

3. Warm up the engine.

4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and water pump for leaks.

   If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

5. Reinstall the reserve tank cap.

INSTALL RADIATOR COVER SUB-ASSEMBLY

1. Install the radiator cover sub-assembly with the 4 clips.