WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A01DW78E03

      Install a new gasket and the pump with the 10 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for bolt A }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for bolt B }

  2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A01DZAVE01

    1. Temporarily install the belt tensioner with the 3 bolts.

      Tech Tips

      Make sure the flanges of the bolts are contacting the tensioner surface.

    2. Install the tensioner with the 3 bolts.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf, for bolt A }
      40 N*m  { 408 kgf*cm, 30 ft.*lbf, for bolt B }
      21 N*m  { 214 kgf*cm, 15 ft.*lbf, for bolt C }

  3. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01DYKNE03

      Install the spacer, pulley and pulley plate with the bolt.

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

  4. INSTALL OIL LEVEL GAUGE GUIDE


    1. Install a new O-ring.

    2. Install the guide with the bolt.

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

  5. INSTALL GENERATOR ASSEMBLY


    1. A01DZY1E03

      Install the generator with the 2 bolts.

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

    2. Install the generator wire with the bolt and nut.

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

    3. Connect the connector.

  6. INSTALL FAN SHROUD

    A01DV6ME03

    1. Install the fan pulley to the water pump.

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

      Note

      Be careful not to damage the radiator core.

    3. Install the coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

    4. Attach the shroud's claws to the radiator as shown in A in the illustration.

    5. Install the shroud with the 2 bolts.

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

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

    7. Install the drive belt.

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  7. INSTALL AIR PUMP INLET (w/ Secondary Air Injection System)


    1. Install the pump inlet to the radiator tank upper with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  8. INSTALL RADIATOR HOSE OUTLET

  9. INSTALL RADIATOR HOSE INLET

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  11. ADD ENGINE COOLANT


    1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for cylinder block drain cock plug }
      Standard capacity
      Item Specified Condition
      Manual transmission w/ Heater 7.8 liters (8.2 US qts, 6.9 Imp. qts)
      w/o Heater 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Automatic transmission w/ Heater 8.1 liters (8.6 US qts, 7.1 Imp. qts)
      w/o Heater 7.3 liters (7.7 US qts, 6.4 Imp. qts)
    2. A01DYUGE01

      Fill the radiator reservoir with TOYOTA Super Long Life Coolant (SLLC) to the F line.

      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).

      • Please contact your TOYOTA dealer for further details.

        Note

        Never use water as a substitute for engine coolant.

    3. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the F line, add TOYOTA SLLC to the F line.

    4. Install the radiator cap.

    5. Bleed air from the cooling system.


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

      2. Maintain the engine speed at 2,500 to 3,000 rpm.

      3. Press the inlet and outlet 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 fan.

    6. Stop the engine and wait until the 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.

    7. A01DYUGE01

      Check the coolant level in the radiator reservoir.

      If the coolant level is below the L line, add SLLC to the reservoir F line.

  12. CHECK FOR ENGINE COOLANT LEAKS


    1. Check for engine coolant leaks Click here.

  13. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  14. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.