WATER PUMP INSTALLATION

INSTALL ENGINE WATER PUMP ASSEMBLY

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
	Bolt A
	Bolt B
	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.

Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

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 }
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.
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, 09963-00700 )
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 ENGINE COVER
1. Install the No. 2 engine cover with the 3 clips.
2. Connect the clamp.
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. 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.
INSTALL NO. 1 ENGINE COVER
1. Install the No. 1 engine cover with the 3 clips.
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.
INSTALL NO. 1 RADIATOR HOSE
1. Install the No. 1 radiator hose to the radiator assembly and secure it with the 2 clamps.

Text in Illustration
*1	Lock Lever

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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

Each Bolt Length is as Follows

Mark	Specified Length
A	70 mm (2.76 in.)
B	35 mm (1.38 in.)

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 }
Tighten the other bolts.

Torque:

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

INSTALL COOLER COMPRESSOR ASSEMBLY
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 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.
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 }
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 }

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 12 or equivalent

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 12 or equivalent

INSTALL FAN AND GENERATOR V BELT

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.

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.
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.
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.

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the 2 cylinder block drain cock plugs.

Torque:

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

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

Standard Capacity

Item	Specified Condition
for LHD	10.9 liters (11.5 US qts, 9.6 Imp. qts)
for RHD	11.0 liters (11.6 US qts, 9.7 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).

Slowly pour coolant into the radiator reservoir tank until it reaches the full line.
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.
Install the radiator cap.
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.
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 the coolant level in the radiator reservoir tank.

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

CHARGE REFRIGERANT
1. for HFC-134a (R134a):
  
  Click here
2. for HFO-1234yf (R1234yf):
  
  Click here
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.
WARM UP ENGINE
1. for HFC-134a (R134a):
  
  Click here
2. for HFO-1234yf (R1234yf):
  
  Click here
INSPECT FOR REFRIGERANT LEAK
1. for HFC-134a (R134a):
  
  Click here
2. for HFO-1234yf (R1234yf):
  
  Click here
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 13 screws and 3 clips.
INSTALL REAR ENGINE UNDER COVER LH
1. Install the rear engine under cover LH with the screw.
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 }
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER
1. Install the engine room side cover with the 4 clips.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. 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).