Installation
2GR-FE COOLING: WATER PUMP: INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Temporarily install a new water pump gasket and the water pump with the 16 bolts.
HINT
Set the water pump pulley onto the water pump when installing the water pump to the engine.
(b) Tighten the 16 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt A
Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf) for bolt B and C
NOTICE:
* Be sure to replace the 2 C bolts with new ones or reuse them after applying adhesive.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
* Make sure that there is no oil on the threads of the A bolts.
2. INSTALL WATER INLET HOUSING
(a) Install a new water inlet housing No. 1 gasket and water outlet pipe O-ring.
(b) Install the water inlet with the 2 bolts and nut.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Be careful not to allow the O-ring to get caught between the parts.
(c) Connect the 2 water hoses.
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 union nut wrench, tighten the 4 bolts.
SST : 09961-00950
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT
* To calculate tightening torque, measure the effective length of the union nut wrench Service Precautions.
* The effective length of SST (09961-00950) is 15 cm (5.9 in.).
4. INSTALL NO. 2 IDLER PULLEY
NOTICE:
The installation of the No. 2 idler pulley differs depending on the mark on the No. 2 idler pulley shown in the illustration.
(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".
5. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install the front No. 1 engine mounting bracket LH with the 6 bolts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTICE:
* Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
* Do not start the engine for at least 2 hours after installation.
HINT
Be sure to insert the bolt (A) into the bolt hole before installing the No. 1 engine mounting bracket LH to the engine.
6. INSTALL ENGINE MOUNTING STAY NO.2 RH
(a) Install the engine mounting stay No. 2 RH with bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
7. INSTALL ENGINE MOUNTING SPACER
(a) Install the engine mounting spacer with the 2 bolts.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
8. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Using a jack, adjust the height of the engine while installing the engine mounting insulator RH with the 5 bolts and nut.
Bolt(A) - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf
Nut(B) - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf
Bolt(C) - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf
(b) Remove the jack.
(c) Install the nut(D).
Nut(D) - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf
(d) Remove the protective tape from the cooler pipe.
(e) Connect the wire harness with the bolt.
Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)
9. INSTALL ENGINE MOUNTING STAY RH
(a) Install the engine mounting stay RH with the bolt and 2 nuts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
10. INSTALL V-RIBBED BELT TENSIONER PULLEY
(a) Install the V-ribbed belt tensioner pulley and dust shield with the bolt.
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.)
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
11. INSTALL CRANKSHAFT PULLEY Reassembly
12. INSTALL V-RIBBED BELT Installation
13. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation
14. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation
15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
16. ADD ENGINE COOLANT Service and Repair
17. INSPECT FOR COOLANT LEAK Testing and Inspection
18. INSTALL REAR ENGINE UNDER COVER RH Installation
19. INSTALL NO. 1 ENGINE UNDER COVER Installation
20. INSTALL REAR WHEEL (for 4WD)
21. INSTALL FRONT WHEEL RH
22. INSTALL RADIATOR SUPPORT OPENING COVER Installation
23. INSTALL V-BANK COVER SUB-ASSEMBLY Installation