GSIC - Global Service Information Center

# WATER PUMP > INSTALLATION

## for Preparation Click here

1. INSTALL WATER PUMP ASSEMBLY

1. Install a new gasket and the water pump with the 6 bolts and 2 nuts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

2. INSTALL NO. 2 TIMING BELT COVER

1. Apply seal packing (FIPG) to the specified areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
     After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

1. Install the No. 2 timing belt cover with the 4 bolts and nut.

   Torque:
     10 N*m{ 102 kgf*cm , 7 ft.*lbf }

3. INSTALL CAMSHAFT TIMING PULLEY

1. Install the camshaft timing pulley.

1. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

   Torque:
     98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }

4. INSTALL TIMING BELT

1. Check that the timing marks are aligned as shown in the illustration.

   HINT:
     If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

   NOTICE:
   1. The engine should be cold.
   2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

1. Using a 10 mm hexagon wrench, install the washer and timing belt idler pulley with the bolt.

   Torque:
     35 N*m{ 357 kgf*cm , 26 ft.*lbf }

1. Check that the idler pulley moves smoothly.
   If it does not move smoothly, check the idler sub-assembly and washer.

1. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

1. Place the tensioner upright. Then set the press to the top of the tensioner.

   NOTICE:
   1. Do not scratch or deform the rod end.
   2. Press in the tensioner rod upward.
   3. Protect the tip of the push rod with a cloth in order to prevent damage.

1. Using a press, slowly push in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

   NOTICE:
     Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) to the push rod.

1. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

1. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

1. Tighten the 2 bolts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

   NOTICE:
     Uniformly tighten the 2 bolts and install the tensioner.

1. Remove the 1.5 mm hexagon wrench from the tensioner.

1. Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

5. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

1. Remove any old seal packing (FIPG) material from the cylinder head.

1. Apply seal packing to the specific areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the belt cover within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 2 hours after installing the seal packing.

1. Install the gasket and cylinder head cover with the 10 bolts and 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install 4 new nozzle holder seals.

7. INSTALL INJECTION PIPE

NOTICE:

1. When replacing the injector, also replace the injection pipe.
2. Keep the joints of the injection pipe clean.

1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

   HINT:
     If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Temporarily install the No. 4 injection pipe with the union nuts.

1. Install 2 new injection pipe clamps with the 2 bolts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

   NOTICE:
   1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.

1. Using SST, tighten the injection pipe union nuts on the common rail side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Using SST, tighten the injection pipe union nuts on the injector side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

8. INSTALL NO. 1 TIMING BELT COVER

1. Install the timing belt cover with the 6 bolts.

   Torque:
     6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

1. Install the wire harness clamp.

1. Install the water hose clamp with the bolt.

   Torque:
     18 N*m{ 184 kgf*cm , 13 ft.*lbf }

9. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

1. Connect the pipe (with the 2 air hoses) and install the bolt.

   Torque:
     20 N*m{ 204 kgf*cm , 15 ft.*lbf }

1. Tighten the 2 clamps of the No. 1 and No. 2 air hoses.

   Torque:
     6.5 N*m{ 66 kgf*cm , 57 in.*lbf }

1. Connect the vacuum hose to the gas filter.

1. Connect the manifold absolute pressure sensor connector.

10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

1. Install the tensioner with the 4 bolts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   HINT:
     Firmly press and hold the tensioner against the cylinder block to eliminate any gaps in the A areas in the illustration. Then uniformly tighten the 4 bolts.

11. INSTALL GENERATOR ASSEMBLY

1. Install the generator and adjusting bar with the 2 bolts.

   Torque:
     62 N*m{ 630 kgf*cm , 46 ft.*lbf } for bolt A
     25 N*m{ 254 kgf*cm , 19 ft.*lbf } for bolt B

1. Install the generator wire with the nut.

   Torque:
     6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

1. Connect the generator connector.

12. INSTALL COOLER COMPRESSOR ASSEMBLY

1. Install the compressor with the 4 bolts.

   Torque:
     24.5 N*m{ 250 kgf*cm , 18 ft.*lbf }

13. INSTALL FAN SHROUD

1. Install the fan pulley to the water pump.

1. Install the shroud together with the coupling fan between the radiator and engine component.

   NOTICE:
     Be careful not to damage the radiator core.

1. Install the fluid coupling fan to the fan pulley with the 4 nuts.
   Tighten the nuts as much as possible by hand.

1. Attach the shroud's claws to the radiator.

1. Install the shroud with the 2 bolts.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

1. Install the drive belt (Click here).

1. Tighten the 4 nuts of the fluid coupling fan.

   Torque:
     18 N*m{ 184 kgf*cm , 13 ft.*lbf }

1. Install the radiator reservoir with the 2 bolts.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

1. Connect the No. 1 and No. 2 water by-pass hoses to the tank upper and lower.

1. Install the oil reservoir with the 3 bolts.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

14. CONNECT RADIATOR HOSE INLET

15. ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

1. Tighten the cylinder block drain cock plug.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

1. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

   Standard capacity:
     9.0 liters (9.5 US qts, 7.9 lmp. qts)

   HINT:
   1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   1. Please contact your TOYOTA dealer for further details.

   NOTICE:
     Never use water as a substitute for engine coolant.

1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
   If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

1. Install the radiator reservoir cap.

1. Using a wrench, install the vent plug.

   Torque:
     2.0 N*m{ 20 kgf*cm , 18 in.*lbf }

1. Bleed air from the cooling system.

   1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

   2. Maintain the engine speed at 2,000 to 2,500 rpm.

   3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:
        When pressing the radiator hoses:
      1. Wear protective gloves.
      1. Be careful as the radiator hoses are hot.
      1. Keep your hands away from the radiator fan.

   4. Stop the engine and wait until the coolant cools down to ambient temperature.

      CAUTION:
        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. After the coolant cools down, check that the coolant level is at the F line.
   If the coolant level is below the F line, add TOYOTA SLLC to the F line.

16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

17. CHECK FOR ENGINE COOLANT LEAKS

1. Check for the engine coolant leaks (Click here).

18. CHECK FOR ENGINE OIL LEAKS

19. INSTALL NO. 1 ENGINE UNDER COVER

1. Install the cover with the 4 bolts.

   Torque:
     28 N*m{ 286 kgf*cm , 21 ft.*lbf }

20. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.