Installation

4GR-FSE COOLING: WATER PUMP: INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 16 bolts.





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolts A

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf) for bolts B and C

NOTICE:
* Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344.
* Make sure that there is no oil on the threads of the A bolts.

2. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the pulley and cover plate with the bolt.





Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

3. INSTALL WATER INLET

(a) Install a new water inlet housing gasket No.1 and water outlet pipe O-ring.





(b) Install the water inlet with the 4 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 parts.

(c) Connect the 5 hoses.





4. INSTALL WATER PUMP PULLEY

(a) Temporarily install the pulley with the 4 bolts.

(b) Using SST, hold the pulley and tighten the 4 bolts.





SST : 09960-10010

09962-01000

09963-00700

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

5. INSTALL NO. 2 ENGINE COVER Installation

6. INSTALL INJECTOR DRIVER Installation

7. INSTALL NO. 1 ENGINE COVER Installation

8. CONNECT RADIATOR HOSE

(a) Connect the radiator inlet hose and radiator outlet hose to the radiator assembly and secure them with the clips.





HINT
* Make sure that the claws on the clips are positioned as shown in the illustration.
* Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.
* Connect the hoses until they make contact with each stopper. (Dimension "b" should be less than 2.5 mm)

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2WD) Installation

11. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (for 4WD) Installation

12. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Installation

13. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

14. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD) Installation

15. INSTALL OIL FILTER BRACKET (for 4WD) Installation

16. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (for 4WD) Installation

17. INSTALL V-RIBBED BELT Installation

18. INSTALL REAR ENGINE UNDER COVER LH (for 2WD) Installation

19. INSTALL ENGINE UNDER COVER

20. INSTALL NO. 1 INLET AIR CLEANER Installation

21. CONNECT BATTERY TERMINAL Installation

22. ADD ENGINE OIL Replacement

23. ADD ENGINE COOLANT Testing and Inspection

24. CHECK FOR ENGINE OIL LEAKS Testing and Inspection

25. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection

26. CHARGE REFRIGERANT Service and Repair

27. START ENGINE

28. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair

29. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

30. INSTALL COOL AIR INTAKE DUCT SEAL Installation