Installation

2GR-FSE COOLING: WATER PUMP: INSTALLATION

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 16 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
- Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344.
- Make sure that there is no oil on the threads of the A bolts.

2. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the pulley and cover plate with the bolt.
Torque: 54 Nm (550 kgf-cm, 40 ft-lbf)
3. INSTALL WATER INLET

(a) Install a new water inlet housing gasket No.1 and water outlet pipe O-ring.

(b) Install the water inlet with the 4 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTE:
Be careful not to allow the O-ring to get caught between parts.

(b) Using SST, hold the pulley and tighten the 4 bolts.
SST: 09960-10010
09962-01000
09963-00700
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
5. INSTALL NO. 2 ENGINE COVER Installation
6. INSTALL INJECTOR DRIVER Installation
7. INSTALL NO. 1 ENGINE COVER Installation
8. CONNECT RADIATOR HOSE

(a) Connect the radiator inlet hose and radiator outlet hose to the radiator assembly and secure them with the clips.
- Make sure that the claws on the clips are positioned as shown in the illustration.
- Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.
- Connect the hoses until they make contact with each stopper. (Dimension "b" should be less than 2.5 mm)

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation
11. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation
12. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation
13. INSTALL V-RIBBED BELT Installation
14. INSTALL REAR ENGINE UNDER COVER LH Installation
15. INSTALL ENGINE UNDER COVER
16. INSTALL NO. 1 INLET AIR CLEANER Installation
17. CONNECT BATTERY TERMINAL Installation
18. ADD ENGINE OIL Replacement
19. ADD ENGINE COOLANT Testing and Inspection
20. CHECK FOR ENGINE OIL LEAKS Testing and Inspection
21. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection
22. CHARGE REFRIGERANT Service and Repair
23. START ENGINE
24. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair
25. INSTALL V-BANK COVER SUB-ASSEMBLY Installation
26. INSTALL COOL AIR INTAKE DUCT SEAL Installation