Water Pump: Installation

INSTALL WATER PUMP ASSEMBLY
1. Install a new water pump gasket and the water pump assembly with the 16 bolts.
  
  Fig 1: Identifying Water Pump Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 21 N*m (214 kgf*cm, 16 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
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  
  Fig 2: Installing Crankshaft Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09213-70011
    1. 09213-70020
  - SST: 09330-00021
  Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
INSTALL WATER INLET HOUSING
1. Install a new water inlet housing gasket and water outlet pipe O-ring.
  
  Fig 3: Identifying Water Inlet Housing Gasket & Water Outlet Pipe O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water inlet housing with the 2 bolts and nut.
  
  Fig 4: Locating Water Inlet Housing And Bolts
  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.
INSTALL WATER PUMP PULLEY
1. Temporarily install the water pump pulley with the 4 bolts.
  
  Fig 5: Locating Water Pump Pulley Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, hold the water pump pulley.
  - SST: 09960-10010
    1. 09962-01000
    2. 09963-00700
3. Tighten the 4 bolts.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
INSTALL V-RIBBED BELT TENSIONER PULLEY
1. Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
  SST: 09961-00950
  
  without SST - Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  with SST - Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  
  NOTICE:
  - 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.)
2. Install the 5 mm bi-hexagon wrench.
Fig 6: Locating V-Ribbed Belt Tensioner Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley cover plate, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly with the bolt.
  
  Fig 7: 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.)
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Place a wooden block between a jack and the engine.
  NOTICE:
  
  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.
  HINT:
  
  Do not jack up the engine excessively.
  
  HINT:
  
  Lift the engine so that bolt A passes above the No. 1 cooler refrigerant suction pipe.
3. Lower the engine, and remove the jack.
  NOTICE:
  
  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.
  Torque: 54 N.m (551 kgf.cm, 40ft.lbf)
5. Using SST, tighten the bolt (A).
  SST: 09249-37010
  
  without SST - Torque: 54 N.m (551 kgf.cm, 40ft.lbf)
  
  with SST - Torque: 39 N.m (398 kgf.cm, 29ft.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: 09249-37010
  
  without SST - Torque: 54 N.m (551 kgf.cm, 40ft.lbf)
  
  with SST - Torque: 39 N.m (398 kgf.cm, 29ft.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.).
INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR NO. 2
1. Install the 3 nuts.
  Torque: 87 N.m (888 kgf.cm, 65ft.lbf)
2. Install the 2 hole plugs.
CONNECT TRANSVERSE ENGINE MOUNTING INSULATOR
1. Install the 3 nuts.
  Torque: 52 N.m (531 kgf.cm, 39ft.lbf)
2. Install the hole plug.
CONNECT REAR ENGINE MOUNTING INSULATOR
1. Install the 2 nuts and transverse engine mounting insulator.
  Torque: 52 N.m (531 kgf.cm, 39ft.lbf)
  
  Fig 13: Locating Rear Engine Mounting Insulator Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 hole plugs.
  
  Fig 14: Locating Hole Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 RADIATOR HOSE
1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 radiator hose to the water inlet.
  
  Fig 15: Identifying No. 2 Radiator Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ENGINE MOUNTING STAY RH
1. Install the bolt, 2 nuts and No. 2 engine mounting stay RH.
  
  Fig 16: Locating Nuts On No. 2 Engine Mounting Stay RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOVING CONTROL ROD
1. Temporarily install the engine moving control rod with the 3 bolts.
2. First install bolts A, and then bolt B.
  Torque: 38 N.m (387 kgf.cm, 28ft.lbf)
CONNECT ENGINE WIRE
1. Install the 3 bolts and disconnect the engine wire.
  
  Fig 18: Identifying Engine Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT
1. Install the V-ribbed belt.
  
  Fig 19: Identifying SST 09249-63010
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09961-00950
2. Using SST, turn the V-ribbed belt tensioner assembly counterclockwise and remove the bar.
3. If it is difficult to install the V-ribbed belt, perform the following procedure:
  1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.
  2. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, and put the V-ribbed belt on the V-ribbed tensioner assembly pulley.
    NOTICE:
    - Put the backside of the V-ribbed belt on the V-ribbed belt tensioner assembly pulley and No. 2 idler pulley sub-assembly.
    - Check that the V-ribbed belt is properly set to each pulley.
  3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crankshaft pulley by hand.
ADD ENGINE COOLANT . Refer to REPLACEMENT .
INSTALL THE V-BANK COVER SUB-ASSEMBLY

Fig 21: Identifying V-Bank Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002