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 N�m (214 kgf�cm, 16ft�lbf)
Bolts (B and C) - Torque: 11 N�m (112 kgf�cm, 8ft�lbf)
NOTICE:
- Make sure that there is no oil on the threads of the bolts (A).
- Be sure to replace the 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 CRANKSHAFT PULLEY
3. 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 N�m (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.
4. 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
09962-01000
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, 16ft�lbf)
with SST - Torque: 11 N�m (112 kgf�cm, 8ft�lbf)
HINT:
- To calculate tightening torque, measure the effective length of the union nut wrench
- The effective length of SST (09961-00950) is 15 cm (5.9 in.).
5. INSTALL V-RIBBED BELT TENSIONER PULLEY
(a) Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
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.
6. 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 N�m (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.)
7. 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 N�m (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.).
8. CONNECT TRANSVERSE ENGINE MOUNTING INSULATOR
(a) Install the 3 nuts.
Torque: 87 N�m (888 kgf�cm, 65ft�lbf)
(b) Install the 2 hole plugs.
9. CONNECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY
(a) Install the 3 nuts.
Torque: 52 N�m (531 kgf�cm, 39ft�lbf)
(b) Install the hole plug.
10. CONNECT REAR ENGINE MOUNTING INSULATOR
(a) Install the 2 nuts.
Torque: 52 N�m (531 kgf�cm, 39ft�lbf)
(b) Install the 2 hole plugs.
11. CONNECT NO. 2 RADIATOR HOSE
12. INSTALL NO. 2 ENGINE MOUNTING STAY RH
13. INSTALL ENGINE MOVING CONTROL ROD
14. INSTALL NO. 2 ENGINE MOUNTING STAY RH
15. CONNECT ENGINE WIRE
(a) Install the engine wire with the 3 bolts.
Torque: 8.4 N�m (86 kgf�cm, 74in�lbf)
16. INSTALL V-RIBBED BELT
17. ADD ENGINE COOLANT
18. INSPECT FOR COOLANT LEAK
19. INSTALL V-BANK COVER SUB-ASSEMBLY