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 (0.0866 to 0.0984 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}

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 wire harness clamp.

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}

Install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts.

Torque:

Bolt A:

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

Bolt B:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Nut A:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Nut B:

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

Install the wire harness clamp bracket with the bolt.

Install the generator assembly with the 2 bolts.

Torque:

Bolt A:

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

Bolt B:

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

Install the wire harness to terminal B with the nut.

Torque:

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

Attach the clamp and connect the generator connector to the generator.

Install the 2 wire harness clamps.

Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the V-ribbed belt.

SST

09216-42010(09216-04010)

NOTICE:

1. Make sure that SST and other tools are set to the tensioner securely.
   
2. When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
   

Tighten the lower radiator drain cock plug.

Tighten the cylinder block drain cock plug.

Torque:

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

Loosen the upper radiator drain cock plug.

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Standard Capacity:

Item	Capacity
Engine coolant	5.7 liters (6.0 US qts, 5.0 lmp. 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).
   
2. Contact your TOYOTA dealer for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Tighten the upper radiator drain cock plug.

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

Install the radiator cap sub-assembly and reservoir tank cap.

Start the engine and warm it up.

Bleed air from the cooling system.

NOTICE:

1. Before starting the engine, turn the A/C switch off.
   
2. Adjust the air conditioning temperature setting to MAX (HOT).
   
3. Adjust the air conditioning blower setting to LO.
   

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

   HINT:

   Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

   CAUTION:

   When squeezing 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 engine coolant cools down.

Add engine coolant to the FULL line on the radiator reservoir.

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

Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 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.

The engine coolant should be between the LOW and FULL lines when the engine is cold.

HINT:

If it is below the LOW line, check for leakage and add Toyota Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line.