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Water Pump: Installation

  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 

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

      Fig 1: Installing Water Pump Assembly With Bolts
      G05828759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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: Locating Idler Pulley Sub-Assembly With Bolt
      G05000201Courtesy 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: Installing Water Inlet Housing Gasket And Water Outlet Pipe O-Ring
      G05828756Courtesy 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: Installing Water Inlet Bolts
      G05828842Courtesy 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: Installing Pulley With Bolts
      G05828754Courtesy 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) 

      Fig 6: Installing Pulley Bolts Using SST
      G05828753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 ENGINE COVER  (See INSTALLATION )
  6. INSTALL INJECTOR DRIVER  (See INSTALLATION )
  7. INSTALL NO. 1 ENGINE COVER  (See INSTALLATION )
  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: Connecting Radiator Hose
        G05828852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY  (See INSTALLATION )
  10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2WD)  (See INSTALLATION )
  11. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 4WD)  (See INSTALLATION )
  12. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)  (See INSTALLATION )
  13. INSTALL OIL FILTER BRACKET (for 4WD)  (See INSTALLATION )
  14. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  15. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE  (See INSTALLATION )
  16. INSTALL V-RIBBED BELT  (See INSTALLATION )
  17. INSTALL REAR ENGINE UNDER COVER LH (for 2WD)  (See INSTALLATION )
  18. INSTALL ENGINE UNDER COVER 
  19. INSTALL NO. 1 INLET AIR CLEANER  (See INSTALLATION )
  20. CONNECT BATTERY TERMINAL  (See INSTALLATION )
  21. ADD ENGINE OIL  (See REPLACEMENT )
  22. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION  )
  23. CHECK FOR ENGINE OIL LEAKS  (See ON-VEHICLE INSPECTION )
  24. CHECK FOR ENGINE COOLANT LEAKAGE  (See ON-VEHICLE INSPECTION  )
  25. CHARGE REFRIGERANT  (See REPLACEMENT )
  26. START ENGINE 
  27. CHECK FOR LEAKAGE OF REFRIGERANT  (See REPLACEMENT )
  28. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  29. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
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