Installation

4GR-FSE COOLING: WATER PUMP: INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 16 bolts.





Bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

Bolt B, C - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

NOTICE:
* Be sure to replace the 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 bolts (A).

2. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the pulley and cover plate with the bolt.





Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

3. INSTALL INLET WATER ASSEMBLY

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





Text in Illustration





(b) Install the inlet water assembly with the 4 bolts and nut.





Text in Illustration





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Be careful not to allow the O-ring to get caught between parts.

(c) Connect the 5 hoses.





4. INSTALL WATER PUMP PULLEY

(a) Temporarily install the pulley with the 4 bolts.

(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 No. 1 radiator hose and No. 2 radiator hose to the radiator assembly, secure them with the clips.





Text in Illustration





HINT
* 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 1.0 to 5.0 mm (0.0393 to 0.196 in.).
* Connect the hoses until they make contact with each stopper (Dimension "b" should be 2.5 mm (0.0984 in.)).

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation

11. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Installation

12. INSTALL 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 INLET NO. 1 AIR CLEANER Installation

17. ADD ENGINE COOLANT Service and Repair

18. CHARGE WITH REFRIGERANT Service and Repair

19. WARM UP ENGINE Service and Repair

20. INSPECT FOR COOLANT LEAK Testing and Inspection

21. INSPECT FOR REFRIGERANT LEAK Service and Repair

22. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

23. INSTALL COOL AIR INTAKE DUCT SEAL Installation