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Installation [12/2015 - 08/2016]: Procedure

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  1. INSTALL WATER PUMP ASSEMBLY 
    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.
      GTY943759Courtesy 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

  2. INSTALL WATER PUMP PULLEY 
    1. Temporarily install the water pump pulley with the 4 bolts.
    2. Using SST, hold the water pump pulley.
      GTY912166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09960-10010 
        1. 09962-01000
        2. 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) 

      HINT: 

      • Use a torque wrench with a fulcrum length of 180 mm (7.09 in.).
      • The effective length of SST (09961-00950) is 150 mm (5.91 in.).
      • The effective length of union nut wrench is 22 mm (0.866 in.).
  3. 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.

      Torque: 54 N*m (551 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.)

      GTY874507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL V-RIBBED BELT TENSIONER PULLEY 
    1. Clean and degrease the bolt seating surface and fastening surface.
    2. Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
      GTY866905Courtesy 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 180 mm (7.09 in.).
      • The effective length of SST (09961-00950) is 150 mm (5.91 in.).
    3. Install the 5 mm bi-hexagon wrench.
  5. INSTALL WATER INLET HOUSING 
    1. Install a new water inlet housing gasket and water outlet pipe O-ring.
      GTY322742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water inlet housing with the 2 bolts and nut.
      GTY914042Courtesy 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.
  6. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Place a wooden block between a jack and the engine.
      GTY888448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      Placement Position
      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 support the specified location with a safety stand.
      GTY911036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Placement Position
      NOTE:

      Do not jack up the engine excessively.

    3. Temporarily install the No. 1 front engine mounting bracket LH with the 2 bolts.
      GTY943787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    4. Lower the engine.
      NOTE:

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

    5. Install the 4 bolts.
      GTY907127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. 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 260 mm (10.2 in.).
      • The effective length of SST (09249-37010) is 100 mm (3.94 in.).
    7. 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 (347 kgf*cm, 25 ft.*lbf) 

      HINT: 

      • Use a torque wrench with a fulcrum length of 260 mm (10.2 in.).
      • The effective length of SST (09961-00950) is 150 mm (5.91 in.).
  7. CONNECT NO. 2 RADIATOR HOSE 

    Refer to PROCEDURE - Step 56

  8. INSTALL NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 17

  9. INSTALL ENGINE MOVING CONTROL ROD 

    Refer to PROCEDURE - Step 46

  10. INSTALL ENGINE MOVING CONTROL ROD BRACKET 

    Refer to PROCEDURE - Step 47

  11. INSTALL NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 48

  12. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Install the 2 nuts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      GTY299460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole plugs.
  13. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the 3 nuts.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

      GTY299462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole plugs.
  14. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Install the 3 nuts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      GTY299456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole plugs.
  15. INSTALL FAN AND GENERATOR V BELT 

    Refer to PROCEDURE - Step 1

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [12/2015 - 08/2016]

  17. ADD ENGINE COOLANT 

    See step  4

  18. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  19. INSTALL NO. 2 ENGINE UNDER COVER (for AWD) 

    Refer to PROCEDURE - Step 14

  20. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 15

  21. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 95

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