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Water Pump: Installation

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL WATER PUMP ASSEMBLY 
    1. Install a new water pump gasket and the water pump assembly with the 16 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts A 

      Fig 1: Identifying Water Pump Assembly Bolts
      G04057760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      9.1 N*m (93 kgf*cm, 81 in.*lbf) for bolts B and C 

      NOTE:
      • Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344.
      • Make sure that there is no oil on the threads of the A bolts.
  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) 

      Fig 2: Identifying Pulley And Cover Plate Bolt
      G04057761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL WATER INLET 
    1. Install a new water inlet housing gasket No.1 and water outlet pipe O-ring.
      Fig 3: Identifying Water Inlet Housing Gasket No 1 And Water Outlet Pipe O-Ring
      G04057762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water inlet 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.
      Fig 4: Identifying Water Inlet Bolts
      G04057763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 5 hoses.
  4. INSTALL WATER PUMP PULLEY 
    1. Temporarily install the pulley with the 4 bolts.
      Fig 5: Identifying Pulley With Bolts
      G04057764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  5. INSTALL NO. 2 ENGINE COVER (See  INSTALLATION  ) 
  6. INSTALL INJECTOR DRIVER (See  INSTALLATION  ) 
  7. INSTALL NO. 1 ENGINE COVER (See  INSTALLATION  ) 
    Fig 6: Identifying Water Pump Pulley And Bolts
    G04057765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT RADIATOR HOSE 
    1. Connect the radiator inlet hose and radiator outlet hose to the radiator assembly and secure them with the clips.

      HINT:

      • Make sure that the claws on the clips are positioned as shown in the illustration.
      • Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.
      • Connect the hoses until they make contact with each stopper. (Dimension "b" should be less than 2.5 mm)
        Fig 7: Identifying Hose Clip Dimension
        G04057766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION  ) 
  10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See  INSTALLATION  ) 
  11. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (See  INSTALLATION  ) 
  12. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (See  INSTALLATION  ) 
  13. INSTALL V-RIBBED BELT (See  INSTALLATION  ) 
  14. INSTALL REAR ENGINE UNDER COVER LH (See  INSTALLATION  ) 
  15. INSTALL ENGINE UNDER COVER 
  16. INSTALL NO. 1 INLET AIR CLEANER (See  INSTALLATION  ) 
  17. CONNECT BATTERY TERMINAL (See  INSTALLATION  ) 
  18. ADD ENGINE OIL (See  REPLACEMENT  ) 
  19. ADD ENGINE COOLANT (See  COOLANT   ) 
  20. CHECK FOR ENGINE OIL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  21. CHECK FOR ENGINE COOLANT LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
  22. CHARGE REFRIGERANT (See  REPLACEMENT  ) 
  23. START ENGINE 
  24. CHECK FOR LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
  25. INSTALL V-BANK COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  26. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
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