INSTALLATION (To 8/2009): Installation

1. Wipe the surface of the timing chain cover where a new water pump gasket and the water pump assembly will be installed.
2. Install a new water pump gasket and the water pump assembly together with the water pump pulley with the 16 bolts.
   Fig 1: Location of Water Pump Assembly And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt A 

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

   Bolts B and C 

   Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

   NOTE:

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

     Adhesive

     Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

1. Temporarily install the water pump pulley with the 4 bolts.
2. Using SST, hold the water pump pulley.
   Fig 2: SST & Water Pump Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09960-10010 
     • 09962-01000
     • 09963-00700
3. Using SST and union nut wrench, tighten the 4 bolts.
   • SST: 09961-00950 

   without SST 

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

   with SST 

   Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

1. Install the idler pulley cover plate, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly with the bolt.
   Fig 3: Identifying Bolt, Idler Pulley Cover Plate, No. 2 Idler Pulley Cover Plate And No. 2 Idler Pulley Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) 

   HINT: 

   Plate diameter:

   Idler pulley cover plate: 33.6 mm (1.32 in.)

   No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)

1. Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
   Fig 4: V-ribbed Belt Tensioner Pulley And Dust Shield With The Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09961-00950 

   without SST 

   Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) 

   with SST 

   Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

   NOTE:

   • Be careful when tightening the bolt because its thread is left-handed.
   • Install the dust shield in the direction shown in the illustration. Failure to do so may cause looseness.
   • Make sure to use the removed bolt. (Do not use another bolt even if it is the same size.)

   HINT: 

   • Use a torque wrench with a fulcrum length of 18 cm (7.09 in.).
   • The effective length of SST (09961-00950) is 15 cm (5.9 in.).
2. Install the 5 mm bi-hexagon wrench.

1. Install a new water inlet housing gasket and water outlet pipe O-ring.
   Fig 5: Identifying O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water inlet housing with the 2 bolts and nut.
   Fig 6: Water Hose, 2 Bolts, Nut And Water Inlet Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   NOTE:

   Be careful not to allow the O-ring to get caught between the parts.

3. Connect the water hose.

1. Place a wooden block between a jack and the engine.
   Fig 7: Set A Jack As Shown

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan.

2. Jack up the engine slightly, and temporarily install the No. 1 front engine mounting bracket LH with the 2 bolts.
   Fig 8: No. 1 Front Engine Mounting Bracket LH With The 2 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Do not jack up the engine excessively.

   HINT: 

   Lift the engine so that the bolt (A) passes above the No. 1 cooler refrigerant suction pipe.

3. Lower the engine, and remove the jack.
   NOTE:

   When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly.

4. Install the 4 bolts.
   Fig 9: 4 Bolts & SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

5. Using SST, tighten the bolt (A).
   • SST: 09249-37010 

   without SST 

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   with SST 

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

   HINT: 

   • Use a torque wrench with a fulcrum length of 26 cm (10.24 in.).
   • The effective length of SST (09249-37010) is 10 cm (3.9 in.).
6. Using SST, tighten the bolt (B).
   • SST: 09961-00950 

   without SST 

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   with SST 

   Torque: 34 N*m (346 kgf*cm, 25 ft.*lbf) 

   HINT: 

   • Use a torque wrench with a fulcrum length of 26 cm (10.24 in.).
   • The effective length of SST (09961-00950) is 15 cm (5.9 in.).

1. Install the 2 nuts
   Fig 10: Identifying Rear Engine Mounting Insulator Assembly, Hole Plugs & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) 

2. Install the 2 hole plugs.

1. Install the 3 nuts.
   Fig 11: Identifying Engine Mounting Insulator RH, Hole Plugs & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) 

2. Install the 2 hole plugs.

1. Install the 3 nuts.
   Fig 12: Identifying Front Engine Mounting Insulator, Hole Plugs & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) 

2. Install the 2 hole plugs.

Refer to INSTALLATION