WATER PUMP > INSTALLATION

for Preparation Click here



1. INSTALL WATER PUMP ASSEMBLY


    A078535

  1. Install a new gasket and the water pump with the 3 bolts and 3 nuts.

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



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

  1. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No.1 with the pivot bolt.

    Torque:
    34 N*m{ 347 kgf*cm , 25 ft.*lbf }



3. INSTALL TIMING BELT NO.3 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.

    HINT:
    If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.



    A078748E01

  1. If the timing belt cover gasket is needed to repair, follow the procedure below.

    1. Repair the cracks and breaks by applying the seal packing to the damaged area.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



  1. If the timing belt cover gasket is needed to replace, follow the procedure below.

    1. Using a screwdriver and gasket scraper, remove the remaining gasket.

      NOTICE:
      Do not damage the timing belt cover.



      2. A078749E01

    2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

      NOTICE:
      1. Affix the gasket in the center of the groove.
      2. At the corners, try to keep the gasket thickness uniform.

      HINT:
      Gasket length
      Gasket
      		D
      		E
      		F
      		G
      Length
      		335 mm
      (13.19 in.)
      		180 mm
      (7.09 in.)
      		133 mm
      (5.24 in.)
      		72 mm
      (2.83 in.)

    3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



    A108157E01

  1. Install the timing belt cover No.3 with the 6 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 76 in.*lbf }



4. INSTALL CAMSHAFT TIMING PULLEY


    A078734E01

  1. Align the alignment pin with the groove and install the VVT-i on the camshaft.

    NOTICE:
    Install it with the lock-pin engaged and locked at the most retard angle position.

  1. Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.

    NOTICE:
    1. Be sure to apply oil, otherwise the specified torque cannot be obtained.
    2. A new nut must be used when replacing the VVT-i unit.



    A005738E01

  1. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.

    Torque:
    150 N*m{ 1,530 kgf*cm , 111 ft.*lbf }

    NOTICE:
    1. The lock nut has left-hand threads.
    2. Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.



5. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2


    A005055

  1. Install the timing belt idler sub-assembly No.2 with the bolt.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }



6. INSPECT TIMING BELT

NOTICE:
  1. Do not bend, twist or turn the timing belt inside out.
  2. Do not allow the timing belt to come into contact with oil, water or steam.
  3. Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects as shown in the illustration. Also, check the points below.


    EM03336E02

  1. If there is premature parting:

    1. Check for proper installation.
    2. Check the timing cover gasket for damage and proper installation.

  1. If the belt teeth are cracked or damaged, check if either camshaft is locked.

  1. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

  1. If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

  1. If there is noticeable wear on the belt teeth:

    1. Check the timing cover for damage.
    2. Check that the gasket has been installed correctly.
    3. Check for foreign object on the pulley teeth.
    If there is any trouble in the belt condition, replace the timing belt.



7. INSTALL TIMING BELT

  1. Remove any oil or water on the pulleys, and keep them clean.

    NOTICE:
    1. If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
    2. Wipe only the pulleys; do not use any cleaning agent.

  1. Inspect the idler pulleys.

    1. Check that the idler pulley turns smoothly.

    2. Visually check the seal portion of the idler pulley for oil leakage.

  1. Inspect the water pump.

    1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.

    2. Visually check the drain hole for coolant leakage.

  1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.



    A082349E01

  1. Turn the crankshaft counterclockwise by approximately 60°.

    NOTICE:
    To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.



    A078751E01

  1. Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No.3 timing belt cover.

    SST
    09960-10010   (09962-01000, 09963-01000)

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



    A005062E01

  1. Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.



    A052840E01

  1. Face the front mark on the timing belt forward.

  1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.

  1. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.



    A078702E02

  1. Install the timing belt in the following order.
    1st
    		Crankshaft timing pulley
    2nd
    		Water pump pulley
    3rd
    		LH camshaft timing pulley
    4th
    		No.2 idler pulley
    5th
    		RH camshaft timing pulley
    6th
    		No.1 idler pulley

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



8. INSTALL CHAIN TENSIONER ASSEMBLY NO.1

  1. Set the timing belt tensioner upright on the press.



    A036238E01

  1. Slowly press in the push rod.

    NOTICE:
    Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

  1. Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Release the press.

  1. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

    Torque:
    27 N*m{ 280 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

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



    A078326E01

  1. Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.

    NOTICE:
    Always turn the crankshaft clockwise.



    A005052E01

  1. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No.3 timing belt cover as shown in the illustration.
    If the marks do not align, remove the timing belt and reinstall it.

  1. Remove the crankshaft pulley bolt.



9. INSTALL TIMING BELT GUIDE NO.2


    A036239E01

  1. Install the timing belt guide with the cup side facing toward the engine front.



10. INSTALL ENGINE MOUNTING BRACKET RH


    A108728

  1. Install the engine mounting bracket RH with the 2 bolts and 2 nuts.

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



11. INSTALL TIMING BELT NO.2 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.



    A108158E01

  1. Install the timing belt cover with the 5 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Connect the 2 clamps.



12. INSTALL TIMING BELT NO.1 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.

  1. Install the timing belt cover.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Install the engine wire protector cover to the timing belt No.3 cover.



13. INSTALL CRANKSHAFT PULLEY


    A108137E01

  1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

  1. Using SST, install the pulley bolt.

    SST
    09213-54015   (91651-60855)
    09330-00021  

    Torque:
    220 N*m{ 2,250 kgf*cm , 162 ft.*lbf }



14. INSTALL ENGINE MOUNTING STAY NO.2 RH


    A108727

  1. Install the engine mounting stay No.2 and the engine mounting bracket No.2 with the bolt.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }



15. INSTALL ENGINE MOVING CONTROL ROD


    A108130E01

  1. Temporarily tighten bolts B and C.

  1. First tighten bolt A, bolt B, then bolt C in this order.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }

  1. Tighten bolt D.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



16. INSTALL AIR CLEANER BRACKET


    A108129

  1. Install the 2 bolts and air cleaner bracket.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }



17. INSTALL RESERVOIR BRACKET


    A108127

  1. Install the 2 bolts, nut and reservoir bracket.

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

  1. Connect the clamp.



18. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    A108126

  1. Install the 2 bolts and brake master cylinder reservoir to the bracket.

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

  1. Connect the connector.



19. INSTALL AIR CLEANER W/RESONATOR


    A109267

  1. Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.



    A106878

  1. Install the air cleaner case w/ resonator with the 5 bolts.

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



    A109270

  1. Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.



    A109893

  1. Connect the ventilation hose No.2.



20. INSTALL AIR CLEANER CAP W/INLET

  1. Install the air cleaner filter element to the air cleaner case.



    A108124

  1. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



21. INSTALL COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.



22. INSTALL BATTERY CARRIER SUB-ASSEMBLY


    A108128

  1. Install the 5 bolts and battery carrier.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



23. INSTALL BATTERY

  1. Install the battery clamp and battery.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }



24. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

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

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



25. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Connect the connector.



26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


27. INSTALL FRONT WIPER ARM & BLADE ASSEMBLY RH


    B108016E03

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



28. INSTALL FRONT WIPER ARM & BLADE ASSEMMBLY LH


    B108016E03

  1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069045E01

  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.



29. INSTALL FRONT FENDER APRON SEAL RH


    A108724

  1. Install the 2 bolts, clip and fender apron seal RH.



30. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    A109416

  1. Install the fender splash shield with the screw.



31. INSTALL FRONT WHEEL RH


32. ADD ENGINE COOLANT

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



33. CHECK FOR ENGINE COOLANT LEAKS


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



34. INSPECT IGNITION TIMING

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up the engine.

  1. When using the intelligent tester:

    1. Connect the intelligent tester (with CAN VIM) to the DLC3.

    2. Enter DATA LIST MODE on the intelligent tester.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      1. Turn all the electrical systems off.
      2. Inspect the engine idle speed with the cooling fan off.

      HINT:
      Refer to the intelligent tester operator's manual if you need help to select DATA LIST.

    3. Check that the ignition timing advances immediately when the engine speed is increased.



    A051075E02

  1. When not using the intelligent tester:

    1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST
      09843-18040  

      NOTICE:
      1. Make sure of the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
      2. Turn off all electrical systems before connecting the terminals.
      3. Perform this inspection after the cooling fan motor is turned off.



      2. A108139

    2. Pull out the red-colored wire harness as shown in the illustration.

    3. Connect the tester terminal of the timing light to the engine.

      NOTICE:
      Use a timing light which detects the first signal.

    4. Inspect ignition timing at idle.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      When checking the ignition timing, the transmission is in neutral.

      HINT:
      Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that the engine rpm returns to idle speed.

    5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

    6. Inspect ignition timing at idle.

      Ignition timing:
      7 to 24° BTDC

    7. Confirm that the ignition timing advances when the engine rpm is increased.

    8. Remove the timing light.



35. PERFORM INITIALIZATION

  1. Some system need initialization when reconnecting the battery cable. (Click here)



36. INSTALL ENGINE ROOM COVER SIDE


    A109835

  1. Install the 5 clips and engine room cover side



37. INSTALL ENGINE ROOM SIDE LH COVER


    A108719

  1. Fit the clips and install the engine room side LH cover.



38. INSTALL ENGINE UNDER COVER NO.1