WATER PUMP INSTALLATION

INSTALL WATER PUMP ASSEMBLY

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.)

INSTALL WATER PUMP PULLEY
1. Temporarily install the pulley with the 4 bolts.
2. 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 }
INSTALL WATER INLET HOUSING
1. Install a new gasket to the water pump.
2. 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. w/ Secondary Air Injection System:
  
  Install the air tube bracket bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. 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.
5. w/ Secondary Air Injection System:
  1. Connect the air pump connector clamp holder.
  2. Attach the wire harness clamp.
  3. Connect the air pump connector.
  4. Connect the No. 2 and No. 3 air hoses.
CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)
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.
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.
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. 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. w/ Air Cooled Transmission Oil Cooler:
  
  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 }
INSTALL NO. 1 RADIATOR HOSE
INSTALL NO. 2 RADIATOR HOSE
INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner with the 3 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL AIR CLEANER HOSE ASSEMBLY
1. 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:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Connect the vacuum hose.
4. Connect the No. 2 ventilation hose.

ADD ENGINE COOLANT

Add engine coolant.

Standard Capacity

Item	Specified Condition
with transmission oil cooler	16.7 liters (17.6 US qts, 14.7 Imp. qts)
without transmission oil cooler	16.2 liters (17.1 US qts, 14.3 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).

Slowly pour coolant into the radiator reservoir until it reaches the F line.
Install the reservoir cap.
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.
Install the radiator cap.
Start the engine and warm it up until the thermostat opens.

Note

Switch off the A/C.
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.
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.
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.
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.

INSPECT FOR COOLANT LEAK
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.
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the upper radiator support seal with the 3 clips.
INSTALL ENGINE ROOM SIDE COVER RH
1. Install the engine room side cover RH with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover LH with the 7 clips.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. 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.
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 }
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 2 screws.
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.