Water Pump Installation

Install a new gasket and the engine water pump assembly with the 17 bolts.

Torque:

for bolt A:

21 N*m{214 kgf*cm, 15 ft.*lbf}

for bolt B:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Text in Illustration

	Bolt A
	Bolt B

Temporarily install the V-ribbed belt tensioner with the 5 bolts.

Install the V-ribbed belt tensioner by tightening bolt 1 and then bolt 2.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Tighten the other bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Bolt Length:

Bolt	Length mm (in.)
A	70 mm (2.76 in.)
B	33 mm (1.30 in.)

Text in Illustration

	Bolt A
	Bolt B

w/ Idler Pulley Cover Plate:

1. Install the 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.
   

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

w/o Idler Pulley Cover Plate:

1. Install the 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.
   

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

for Integrated Type:

1. Install the 2 No. 2 idler pulleys with the 2 bolts.
   

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

Install a new O-ring to the water outlet pipe.

Install a new gasket to the water pump.

Apply soapy water to the O-ring.

Install the water inlet assembly to the 5 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Connect the 5 water by-pass hoses.

Install the 2 radiator hoses to the water inlet assembly.

Connect the No. 2 PCV hose and clamp.

Install the fan pulley to the water pump.

Place the shroud together with the coupling fan between the radiator and engine.

NOTICE:

Be careful not to damage the radiator core.

Install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

Attach the shroud's claws to the radiator as shown in the illustration.

Install the shroud with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the reservoir hose to the radiator tank upper.

Install the fan and generator V belt (HILUX_TGN26 RM000000YN200BX_01_0001.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the oil reservoir with the 3 bolts.

Torque:

5.0 N*m{46 kgf*cm, 40 in.*lbf}

Connect the radiator hose inlet to the radiator.

Connect the radiator hose outlet to the radiator.

Tighten the 2 cylinder block water drain cock plugs.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Add engine coolant.

Standard capacity:

9.8 liters (10.4 US qts, 8.6 Imp. qts)

NOTICE:

Never use water as a substitute for engine coolant.

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Press the radiator hose inlet and radiator hose outlet several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the radiator hose inlet will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the radiator hose inlet and radiator hose outlet several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the radiator hose outlet by hand and checking when the engine coolant starts to flow inside the hose.
   

Stop the engine and wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

Remove the radiator cap.

CAUTION:

To avoid being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.
If the pressure drops, check the hose, radiator and water pump for leakage. If no external leakage is found, check the heater core, cylinder block and cylinder head.

Install the radiator cap.

Install the air cleaner with the 2 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Tighten the 2 hose clamps.

Attach the 2 wire harness clamps.

Connect the mass air flow meter connector.

Connect the vacuum hose.

Install the V-bank cover with the 2 nuts.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}