WATER PUMP INSTALLATION


  1. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01FGK0E01

      Install a new water pump gasket and the engine water pump assembly with the 16 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B, C
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Text in Illustration
      A01FGIV Bolt A
      A01FJ4N Bolt B
      A01FI67 Bolt C

      Note


      • Be sure to apply adhesive to the 2 bolts labeled C before reusing them, or replace them with new ones if necessary.

        Adhesive
        Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      • Make sure that there is no oil on the threads of the bolts labeled A.

      Standard length
      Item Length
      Bolt A 55 mm (2.17 in.)
      Bolt B, C 22 mm (0.87 in.)

  2. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the pulley and cover plate with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  3. INSTALL WATER INLET ASSEMBLY


    1. Install a new No. 1 water inlet housing gasket and water outlet pipe O-ring.

    2. Install the water inlet assembly with the 4 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 parts.

    3. Connect the 5 hoses.

  4. INSTALL WATER PUMP PULLEY


    1. Temporarily install the pulley with the 4 bolts.

    2. A01FHMUE03

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

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  5. INSTALL NO. 2 ENGINE COVER


    1. Install the No. 2 engine cover with the 3 clips.

    2. Connect the clamp.

  6. INSTALL INJECTOR DRIVER

    Note


    • Be careful not to drop or strike the injector driver.

    • The injector driver is grounded at the bolt and nut. To ensure that it is grounded, clean all oil and foreign matter from the installation areas of the injector driver and engine before installing the injector driver.


    1. Install the injector driver with the bolt and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01FF5JE01
      Text in Illustration
      *1 Lock Lever

      Connect the 4 connectors to the injector driver. Move the lock levers in the direction indicated by the arrow to lock the 3 connectors.

  7. INSTALL NO. 1 ENGINE COVER


    1. Install the No. 1 engine cover with the 3 clips.

  8. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and secure it with the clip.

  9. INSTALL NO. 1 RADIATOR HOSE


    1. Install the No. 1 radiator hose to the radiator assembly and secure it with the 2 clamps.

  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01FF8NE05
      Text in Illustration
      *A for 2WD
      *B for AWD

      for 2WD:

      Temporarily install the V-ribbed belt tensioner with the 5 bolts.

    2. for AWD:

      Temporarily install the V-ribbed belt tensioner with the 4 bolts.

      Each Bolt Length is as Follows
      Mark Specified Length
      A 70 mm (2.76 in.)
      B 35 mm (1.38 in.)

    3. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

    4. Tighten the other bolts.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

  11. INSTALL COOLER COMPRESSOR ASSEMBLY (for 2WD)


    1. A01FIYJE01

      Using an E8 "torx" socket, install the cooler compressor assembly with the stud bolt.

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

    2. Install the cooler compressor assembly with the 3 bolts and nut.

      Torque:
      for bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      for nut
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the cooler compressor assembly.

  12. INSTALL COOLER COMPRESSOR ASSEMBLY (for AWD)


    1. Using an E8 "torx" socket, install the cooler compressor assembly with the stud bolt.

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

    2. Install the cooler compressor assembly with the 2 bolts and nut.

      Tech Tips

      Temporarily install the bolts and nut.

  13. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for AWD)


    1. Install a new oil filter bracket gasket and the oil filter bracket sub-assembly with the 2 nuts and bolt.

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

    2. Install the wire harness to connect the connector and attach the 2 clamps.

  14. INSTALL OIL FILTER BRACKET (for AWD)


    1. Install the oil filter bracket with the bolt and nut.

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

      Tech Tips

      Temporarily install the bolt.

  15. TIGHTEN COOLER COMPRESSOR ASSEMBLY (for AWD)


    1. A01FFK1E01

      Install the cooler compressor assembly with the 3 bolts and nut.

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

      Note

      Tighten the bolts in the order shown in the illustration to install the cooler compressor assembly.

  16. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

    2. for HFC-134a (R134a):

      Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. for HFO-1234yf (R1234yf):

      Apply sufficient compressor oil (ND-OIL 12) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil
      ND-OIL 12 or equivalent

    4. Install the O-ring on the No. 1 cooler refrigerant discharge hose.

    5. Install the No. 1 cooler refrigerant discharge hose on the cooler compressor assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  17. CONNECT SUCTION HOSE


    1. Remove the attached vinyl tape from the suction hose.

    2. for HFC-134a (R134a):

      Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. for HFO-1234yf (R1234yf):

      Apply sufficient compressor oil (ND-OIL 12) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil
      ND-OIL 12 or equivalent

    4. Install the O-ring on the suction hose.

    5. Install the suction hose on the cooler compressor assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  18. INSTALL FAN AND GENERATOR V BELT


    1. A01FFUOE03
      Text in Illustration
      *1 Engine Water Pump
      *2 Generator
      *3 Idler
      *4 Tensioner
      *5 Crankshaft
      *6 A/C Compressor

      Set the V belt onto every part.

    2. While turning the belt tensioner counterclockwise, remove the bar.

      Note


      • Put the backside of the V belt on the tensioner pulley and idler pulley.

      • Check that the V belt is properly set to each pulley.

    3. If it is difficult to install the V belt, perform the following procedure.


      1. Put the V belt on every part except the tensioner pulley.

      2. Put the V belt on the tensioner pulley while turning the belt tensioner counterclockwise.

        Note


        • Put the backside of the V belt on the tensioner pulley and idler pulley.

        • Check that the V belt is properly set to each pulley.

    4. Check that the belt fits properly in the ribbed grooves.

      Tech Tips

      Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

  19. ADD ENGINE OIL (for AWD)


    1. Add clean engine oil.

      Note

      Do not allow engine oil to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

      A01FF7U

      If engine oil is on the location indicated by the arrow, replace the belt tensioner.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)

      • API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

      • 5W-30

      • 10W-30
      API grade SL, SM or SN multigrade engine oil

      • 15W-40

      • 20W-50
      Standard Oil Grade (for Korea)
      Oil Grade Oil Viscosity (SAE)

      • API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

      • 0W-20

      • 5W-20

      • 5W-30

      • 10W-30
      API grade SL, SM or SN multigrade engine oil

      • 15W-40

      • 20W-50
      Standard Capacity
      Item Specified Condition (for 2WD) Specified Condition (for AWD)
      Drain and refill without oil filter change 5.9 liters (6.2 US. qts., 5.2 Imp. qts.) 6.0 liters (6.3 US. qts., 5.3 Imp. qts.)
      Drain and refill with oil filter change 6.3 liters (6.7 US. qts., 5.5 Imp. qts.) 6.4 liters (6.7 US. qts., 5.6 Imp. qts.)
      Dry fill 7.2 liters (7.6 US. qts., 6.3 Imp. qts.) 7.7 liters (8.1 US. qts., 6.8 Imp. qts.)

    2. Install the oil filler cap.

  20. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Add TOYOTA Super Long Life Coolant (SLLC) to the water outlet sub-assembly opening.

      Standard Capacity
      Item Specified Condition
      w/o Transmission Oil Cooler 9.7 liters (10.3 US qts, 8.5 Imp. qts)
      w/ Transmission Oil Cooler 10.0 liters (10.6 US qts, 8.8 Imp. 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).

    4. Slowly pour coolant into the radiator reservoir tank until it reaches the full line.

    5. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    6. Install the radiator cap.

    7. Bleed air from the cooling system.

      Note

      Before starting the engine to warm up the engine, turn the A/C switch off.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.


        • Be careful as the radiator hoses are hot.


        • Keep your hands away from the radiator fans.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

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

      3. Press the No. 1 and No. 2 radiator hoses 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 fans.

    8. 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.

    9. Check the coolant level in the radiator reservoir tank.

      If the coolant level is low, add SLLC to the radiator reservoir tank full line.

  21. CHARGE REFRIGERANT


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  22. INSPECT FOR OIL LEAK (for AWD)


    1. Start the engine. Make sure that no oil leaks from the connection point of the oil filter cap.

  23. INSPECT ENGINE OIL LEVEL


    1. Warm up and stop the engine, and then wait for 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.

      If low, check for leakage and add oil up to the full level mark.

      Note

      Do not add engine oil to above the full level mark.

  24. INSPECT FOR COOLANT LEAK

    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.

    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 137 kPa (1.4 kgf/cm2, 20 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.

  25. WARM UP ENGINE


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  26. INSPECT FOR REFRIGERANT LEAK


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  27. INSTALL REAR ENGINE UNDER COVER LH (for 2WD)


    1. Install the rear engine under cover LH with the screw.

  28. INSTALL ENGINE UNDER COVER


    1. for 2WD:


      1. Install the engine under cover with the 13 screws and 3 clips.

    2. for AWD:


      1. Install the engine under cover with the 10 screws and 3 clips.

  29. INSTALL NO. 1 AIR CLEANER INLET


    1. Install the No. 1 air cleaner inlet with the bolt.

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

  30. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 7 clips.

  31. INSTALL ENGINE ROOM SIDE COVER


    1. Install the engine room side cover with the 4 clips.

  32. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01FGFXE01
      Text in Illustration
      *1 Tip (Round Portion)

      Attach the 3 clips in the order shown in the illustration to install the V-bank cover.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

      • Do not apply any oil to the tips (round portions).