Water Pump (For Hatchback) Installation

Install the water pump assembly through a new water pump gasket with the 3 bolts and 2 nuts.

Torque:

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

Provisionally install the water pump pulley with the 3 bolts.

Using SST, hold the water pump pulley.

SST

09960-10010(09962-01000,09963-00700)

Tighten the 3 bolts to the specified torque.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the engine mounting insulator RH with the 5 bolts.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Temporarily install the generator assembly with the fixing bolt.

Install the piping clamp with the bolt A and screw B.

Torque:

Bolt A:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Temporarily install the fan belt adjusting slider with fan belt adjusting slider fixing bolt A and nut B.

Move generator assembly toward the cylinder block and tighten nut B.

Torque:

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

Connect the connector and engage the clamp.

Install the wire harness to terminal B with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Provisionally install the fan and generator V belt onto each pulley.

NOTICE:

1. Make sure that there is no foreign matter or liquid, such as oil, on the belt and pulleys.
   
2. Make sure that the V belt is securely fitted into the rib grooves of the pulley.
   

Insert an adjusting bar between the engine mounting bracket and generator assembly. Pull the adjusting bar toward the vehicle front to adjust the generator V belt tension.

Text in Illustration

*a	OK
*b	NG
	Front of Vehicle

NOTICE:

Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the camshaft timing oil control valve assembly.

First tighten bolt A, then tighten bolt B.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf} for bolt A

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

Check the fan and generator V belt for wear, cracks or other signs of damage.
If any of the following defects is found, replace the fan and generator V belt.

1. The fan and generator V belt is cracked.
   
2. The fan and generator V belt is worn out to the extent that the cords are exposed.
   
3. The fan and generator V belt has chunks missing from the ribs.
   

Check that the fan and generator V belt fits properly in the ribbed grooves.

HINT:

Check with your hand to confirm that the fan and generator V belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly.

Inspect the V belt deflection and tension.

Deflection:

Item	Specified Condition
New belt	8.0 to 9.0 mm (0.31 to 0.35 in)
Used belt	12.5 to 13.5 mm (0.49 to 0.53 in)

Tension:

Item	Specified Condition
New belt	700 to 800 N (71 to 82 kg, 157 to 180 lb)
Used belt	300 to 400 N (31 to 41 kg, 67 to 90 lb)

HINT:

1. When inspecting the V belt deflection, apply 98 N (10 kgf) tensile force to it.
   
2. Perform the V belt inspection and adjustment while the engine is cold.
   
3. V-ribbed belt tension and deflection should be checked immediately after installation of a new belt, and after cranking the engine when inspecting a used belt.
   
4. Check the V belt deflection at the point between the specified pulleys where the deflection is greatest.
   
5. When installing a new belt, set its tension to the intermediate value of the specification.
   
6. When inspecting a belt which has been used for over 5 minutes, apply the Used Belt specifications.
   
7. When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each Used Belt specification.
   
8. V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking.
   
9. When using a belt tension gauge, confirm its accuracy by using a master gauge first.
   

Tighten the cylinder block drain cock plug and the radiator drain cock plug.

Torque:

13 N*m{133 kgf*cm, 9.6 ft.*lbf}

Pour engine coolant into the radiator assembly until it is full.

Standard capacity:

5.0 liters (5.3 US qts, 4.4 Imp. qts)

NOTICE:

Do not substitute water for coolant.

HINT:

1. Use of improper engine coolant may damage the engine coolant system.
   
2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).
   

Check the coolant level inside the radiator assembly by squeezing the No. 2 radiator hose and the No. 3 radiator hose several times by hand. If the coolant level goes down, add engine coolant.

Install the water filler cap sub-assembly securely.

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

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens.
   While the thermostat is open, circulate the coolant for several minutes.
   

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the coolant starts to flow inside the hose.

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the No. 2 radiator hose and No. 3 radiator hose several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

Stop the engine and wait until the coolant cools down.

If the coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the coolant level stays at the full level.

Recheck the coolant level inside the radiator reservoir tank assembly. If it is below the full level, add coolant.

Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

Pump the tester to 137 kPa (1.4 kgf/cm², 19.9 psi), then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Install the engine under cover RH with the 3 screws and 2 bolts.

Torque:

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