Water Pump Installation

Remove any old seal packing material from the contact surface.

Apply a continuous line of seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

Standard seal diameter:

2.2 to 2.5 mm (0.09 to 0.10 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.
   

Install the water pump and clamp bracket with the 4 bolts and 2 nuts.

Torque:

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

Install the wire of the crankshaft position sensor onto the clamp bracket.

Install the clamp of the crankshaft position sensor onto the water pump.

Using SST, install the water pump pulley with the 4 bolts.

SST

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

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Install the generator with the 2 bolts.

Torque:

21 N*m{215 kgf*cm, 16 ft.*lbf}for bolt A

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

Install the wire harness clamp.

Install the wire harness clamp bracket with the bolt.

Torque:

8.4 N*m{85 kgf*cm, 74 in.*lbf}

Connect the generator wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Install the terminal cap.

Connect the generator connector.

Using SST 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then install the fan and generator V belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

Install the reinforcement RH with the 4 bolts.

Torque:

96 N*m{989 kgf*cm, 71 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

12.7 N*m{130 kgf*cm, 10 ft.*lbf}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Continue adding TOYOTA SLLC until it is filled to the B line at the base of the reservoir's filler neck.

HINT:

The B line is the lower edge of the inner wall of the filler neck.

Standard capacity:

Item	Specified Condition
A/T	6.4 liters (6.8 US qts, 5.6 Imp. qts)
M/T	6.3 liters (6.7 US qts, 5.5 Imp. qts)

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).
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Start the engine and warm it up until the cooling fan operates. While the cooling fan operates, circulate the coolant for several minutes.

1. Set the air conditioning as follows while warming up the engine.
   

   Item	Specified Condition
   Manual Air Conditioning System	Fan speed: Any setting except OFF
   	Temperature: Toward WARM Air conditioning switch: OFF
   Automatic Air Conditioning System	Temperature: Toward MAX Air conditioning switch: OFF

2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.
   

   NOTICE:

   1. Make sure that the radiator reservoir still has some coolant in it.
      
   2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
      
   3. If there is not enough coolant, the engine may burn out or overheat.
      
   4. 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 B line.
      
   5. Run the engine at 2,000 rpm until the coolant level has stabilized.
      

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

CAUTION:

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 to ambient temperature.

Check that the coolant level is between the FULL and LOW line.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

Remove the radiator reservoir cap.

CAUTION:

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

Fill the radiator reservoir with coolant, and then attach a radiator cap tester.

Warm up the engine.

Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

Reinstall the radiator cap.