INSTALL ENGINE WATER PUMP ASSEMBLY

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

CONNECT VANE PUMP ASSEMBLY

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

INSTALL WATER INLET HOUSING

CONNECT AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)

INSTALL FAN SHROUD

CONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)

INSTALL NO. 2 RADIATOR HOSE

INSTALL NO. 1 RADIATOR HOSE

INSTALL V-BANK COVER

ADD ENGINE COOLANT

INSPECT FOR COOLANT LEAK

INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

INSTALL COOLER COMPRESSOR ASSEMBLY

INSTALL GENERATOR ASSEMBLY

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

• Torque:
• for bolt A:
• 47 N*m{ 479 kgf*cm, 35 ft.*lbf}
• for bolt B:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}
• for bolt C:
• 23 N*m{ 235 kgf*cm, 17 ft.*lbf}

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

• Standard Bolt:

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

Text in Illustration

	Bolt A
	Bolt B

Tighten bolts 1 and 2 in numerical order.

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

Tighten the other bolts.

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

Connect the vane pump with the 2 bolts.

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

Attach the wire harness clamp.

Connect the connector.

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 gasket of the water outlet pipe.

Install the water inlet with the 5 bolts.

• Torque:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Connect the 5 water by-pass hoses.

Connect the oil cooler hose.

Connect the No. 2 oil cooler hose.

Connect the throttle body connector.

Connect the air tube with the 2 bolts.

• Torque:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

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.

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

• NOTICE:

• Match the paint marks on the heads of the water pump studs with the paint marks on the flange of the fluid coupling and install the fluid coupling.

Attach the claws of the shroud to the radiator as shown in the illustration.

Install the shroud with the 2 bolts.

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

Connect the reservoir hose to the upper side of the radiator tank.

Install the fan and generator V-belt ().

Tighten the 4 nuts of the fluid coupling fan.

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

Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

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

Install the No. 2 radiator hose and attach the clamp.

Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

Add engine coolant.

• Standard Capacity (for Manual transmission):

• Item	Specified Condition
  w/ Rear Heater	14.6 liters (15.4 US qts, 12.8 Imp. qts)
  w/o Rear Heater	11.7 liters (12.4 US qts, 10.3 Imp. qts)

• Standard capacity (for Automatic transmission):
• 11.2 liters (11.8 US qts, 9.9 Imp. qts)

• Standard Capacity (for China):
• 14.4 liters (15.2 US qts, 12.7 Imp. qts)

• NOTICE:

• Do not substitute plain water for engine coolant.

• HINT:

• 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).

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

Install the reservoir cap.

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

Install the radiator cap.

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

Start the engine and warm it up until the thermostat opens.

• HINT:

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

Maintain the engine speed at 2000 to 2500 rpm.

• NOTICE:

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

• CAUTION:

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

• 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.

Check that the coolant level is between the F and L lines.

If the coolant level is below the L line, repeat all of the procedures above.

If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and then check that the pressure does not drop.

If the pressure drops, check the hoses, radiator and engine water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Install the No. 1 engine under cover with the 10 bolts.

• Torque:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.