Installation
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Wipe the surface of the timing chain cover where a new water pump gasket and the water pump assembly will be installed.
(b) Install a new water pump gasket and the water pump assembly together with the water pump pulley with the 16 bolts.
Bolt A - Torque: 21 Nm (214 kgf cm, 15ft lbf)
Bolts B and C - Torque: 11 Nm (112 kgf cm, 8ft lbf)
NOTICE:
Make sure that there is no oil on the threads of bolts A. Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. INSTALL WATER PUMP PULLEY
(a) Temporarily install the water pump pulley with the 4 bolts.
(b) Using SST, hold the water pump pulley.
SST: 09960-10010
SST: 09962-01000
SST: 09963-00700
(c) Using SST and union nut wrench, tighten the 4 bolts.
SST: 09961-00950
without SST - Torque: 21 N�m (214 kgf�cm, 15ft�lbf)
with SST - Torque: 11 N�m (112 kgf�cm, 8ft�lbf)
3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley cover plate, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly with the bolt.
Torque: 54 Nm (550 kgf cm, 40ft lbf)
HINT:
Plate diameter:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
4. INSTALL V-RIBBED BELT TENSIONER PULLEY
(a) Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
SST: 09961-00950
without SST - Torque: 48 N�m (489 kgf�cm, 35ft�lbf)
with SST - Torque: 26 N�m (265 kgf�cm, 19ft�lbf)
NOTICE:
Be careful when tightening the bolt because its thread is left-handed.
Install the dust shield in the direction shown in the illustration. Failure to do so may cause looseness. Make sure to use the removed bolt. (Do not use another bolt even if it is the same size.)
HINT:
Use a torque wrench with a fulcrum length of 18 cm (7.09 in.).
The effective length of SST (09961-00950) is 15 cm (5.9 in.).
(b) Install the 5 mm bi-hexagon wrench.
5. INSTALL WATER INLET HOUSING
(a) Install a new water inlet housing gasket and water outlet pipe O-ring.
(b) Install the water inlet housing with the 2 bolts and nut.
Torque: 10 Nm (102 kgf cm, 7ft lbf)
NOTICE:
Be careful not to allow the O-ring to get caught between the parts.
(c) Connect the water hose.
6. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
(a) Place a wooden block between a jack and the engine.
NOTICE:
Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan.
(b) Jack up the engine slightly, and temporarily install the No. 1 front engine mounting bracket LH with the 2 bolts.
NOTICE:
Do not jack up the engine excessively.
HINT:
Lift the engine so that the bolt (A) passes above the No. 1 cooler refrigerant suction pipe.
(c) Lower the engine, and remove the jack.
NOTICE:
When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly.
(d) Install the 4 bolts.
Torque: 54 Nm (551 kgf cm, 40ft lbf)
(e) Using SST, tighten the bolt (A).
SST: 09249-37010
without SST - Torque: 54 N�m (551 kgf�cm, 40ft�lbf)
with SST - Torque: 39 N�m (398 kgf�cm, 29ft�lbf)
HINT:
Use a torque wrench with a fulcrum length of 26 cm (10.24 in.).
The effective length of SST (09249-37010) is 10 cm (3.9 in.).
(f) Using SST, tighten the bolt (B).
SST: 09961-00950
without SST - Torque: 54 N�m (551 kgf�cm, 40ft�lbf)
with SST - Torque: 34 N�m (346 kgf�cm, 25ft�lbf)
HINT:
Use a torque wrench with a fulcrum length of 26 cm (10.24 in.).
The effective length of SST (09961-00950) is 15 cm (5.9 in.).
7. INSTALL NO. 2 RADIATOR HOSE
8. INSTALL NO. 2 ENGINE MOUNTING STAY RH
9. INSTALL ENGINE MOVING CONTROL ROD
10. INSTALL ENGINE MOVING CONTROL ROD BRACKET
11. INSTALL NO. 2 ENGINE MOUNTING STAY RH
12. CONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY
(a) Install the 2 nuts
Torque: 52 Nm (531 kgf cm, 39ft lbf)
(b) Install the 2 hole plugs.
13. CONNECT ENGINE MOUNTING INSULATOR RH
(a) Install the 3 nuts.
Torque: 87 Nm (888 kgf cm, 65ft lbf)
(b) Install the 2 hole plugs.
14. CONNECT FRONT ENGINE MOUNTING INSULATOR
(a) Install the 3 nuts.
Torque: 52 Nm (531 kgf cm, 39ft lbf)
(b) Install the 2 hole plugs.
15. INSTALL V-RIBBED BELT
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Testing and Inspection
17. ADD ENGINE COOLANT
18. INSPECT FOR COOLANT LEAK
19. INSTALL NO. 2 ENGINE UNDER COVER
20. INSTALL NO. 1 ENGINE UNDER COVER
21. INSTALL V-BANK COVER SUB-ASSEMBLY
22. INSTALL COOL AIR INTAKE DUCT SEAL
23. INSTALL ENGINE ROOM SIDE COVER LH
24. INSTALL ENGINE ROOM SIDE COVER