Installation

1GR-FE COOLING: WATER PUMP: INSTALLATION

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 17 bolts.
10 mm (0.39 in.) head - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
12 mm (0.47 in.) head - Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
3. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
4. INSTALL GENERATOR ASSEMBLY Installation
5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

NOTE: The installation of the No. 2 idler pulleys differs depending on the mark on the No. 2 idler pulleys shown in the illustration.





HINT: Use the same procedure for both No. 2 idler pulleys.

(a) w/ Idler Pulley Cover Plate (PU107013ARMXY3):




(1) Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTICE:
- If it is necessary to replace the pulley or either plate, replace the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate as a set with new parts.
- When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".

(b) w/o Idler Pulley Cover Plate (PU107013ARMXY1):




(1) Install the idler pulley and No. 2 idler pulley cover plate with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTICE:
- If it is necessary to replace the pulley or plate, replace both the pulley and plate with a set of new parts that includes a No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate.
- When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".

6. INSTALL WATER INLET





(a) Install a new O-ring to the water outlet pipe.
(b) Install a new gasket to the water pump.
(c) Apply soapy water to the O-ring.





(d) Install the water inlet with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Connect the 5 water by-pass hoses.
(f) Connect the 2 radiator hoses.
(g) Connect the 2 oil cooler hoses (with oil cooler).
7. INSTALL AIR CLEANER ASSEMBLY
8. CONNECT VENTILATION HOSE NO.2
9. INSTALL FAN WITH FLUID COUPLING
(a) Put the fan pulley to the water pump.
(b) Put the fan with fluid coupling and fan shroud together.
(c) Temporarily install the 4 fluid coupling nuts.
(d) Tighten the 2 fan shroud bolts and radiator reserve tank bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(e) Connect the reserve tank hose.
(f) Fasten the 2 oil cooler hoses with the hose clamp.
10. INSTALL FAN AND GENERATOR V BELT Installation
11. FULLY TIGHTEN FAN WITH FLUID COUPLING
(a) Tighten the 4 fluid coupling bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
12. INSTALL RADIATOR SUPPORT SEAL UPPER
13. ADD ENGINE COOLANT Service and Repair
14. INSPECT ENGINE COOLANT LEAK Service and Repair
15. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
16. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
(a) Install the engine under cover with the 4 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)