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, 15ft�lbf)
Bolt (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 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.
3. 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 a union nut wrench, tighten the 4 bolts.
SST: 09961-00950
without SST - Torque: 21 N�m (214 kgf�cm, 15ft�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.).
4. 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.
5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley cover plate, No. 2 idler pulley sub-assembly (FR Side) and No. 2 idler pulley cover plate 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.)
(b) Using SST, install the idler pulley cover plate, No. 2 idler pulley sub-assembly (RR Side) and No. 2 idler pulley cover plate with the bolt.
without SST - Torque: 54 N�m (550 kgf�cm, 40ft�lbf)
with SST - Torque: 34 N�m (347 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.).
Plate diameter:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
6. CONNECT RADIATOR OUTLET HOSE
7. INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH
(a) Install the No. 1 engine front mounting bracket LH with the 7 bolts.
Bolt (A) - Torque: 8.4 N�m (85 kgf�cm, 74in�lbf)
Bolt (B) - Torque: 54 N�m (551 kgf�cm, 40ft�lbf)
8. INSTALL NO. 2 ENGINE MOUNTING STAY RH
9. INSTALL TRANSVERSE ENGINE MOUNTING CONTROL BRACKET
(a) Install the transverse engine mounting control bracket with the 2 bolts.
Torque: 38 N�m (388 kgf�cm, 28ft�lbf)
10. INSTALL NO. 2 ENGINE MOUNTING STAY RH
11. CONNECT ENGINE MOVING CONTROL ROD
(a) Rotate the engine moving control rod to the side as shown in the illustration.
(b) Install the No. 3 engine mounting stay RH with the bolt.
Torque: 78 N�m (795 kgf�cm, 57ft�lbf)
(c) Install the bolt (B).
Torque: 44 N�m (449 kgf�cm, 32ft�lbf)
(d) Tighten the bolt (A).
Torque: 38 N�m (388 kgf�cm, 28ft�lbf)
12. INSTALL V-RIBBED BELT
13. INSTALL FRONT FENDER APRON SEAL RH
14. INSTALL FRONT WHEEL RH
15. ADD ENGINE COOLANT
16. INSPECT FOR COOLANT LEAK
17. INSTALL V-BANK COVER SUB-ASSEMBLY