Page 294 of 4770
(See Components for Removal and Installation)
1. INSTALL THERMOSTAT AND WATER INLET TO
WATER PUMP COVER
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the upper
side of the stud bolt, and insert the thermostat in the
water pump.
HINT: The jiggle valve may be set within 5 of either
side of the prescribed position. 10. REMOVE WATER INLET AND THERMOSTAT FROM
WATER PUMP COVER
(a) Remove the 2 nuts and water inlet from the water
pump.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.
WATER PUMP INSPECTION
INSPECT WATER PUMP
Turn the pulley and check that the water pump bear±
ing moves smoothly and quietly.
(c) Install the water inlet with the 2 nuts.
Torque: 8.8 N±m (90 kgf±cm. 78 in.±lbf)
WATER PUMP INSTALLATION
± 5S±FE ENGINECOOLING SYSTEMEG1±244
Page 295 of 4770
2. ASSEMBLE WATER PUMP AND WATER PUMP
COVER
Install a new gasket and the water pump to the pump
cover with the 3 bolts.
Torque: 9.3 N±m (95 kgf±cm, 82 In.±lbf)
(c) Apply soapy water to the O±ring on the water bypass
pipe.
(d) Connect the pump cover to the water bypass pipe.
Do not install the nuts yet. 3. INSTALL WATER PUMP AND WATER PUMP
COVER ASSEMBLY
(a) Install new O±ring and gasket to water pump cover.
(e) Install the water pump with the 3 bolts. Tighten the
bolts in the sequence shown.
Torque: 9.3 N±m (95 kgf±cm, 82 in.±lbf)
(b) Instal a new O±ring to the water bypass pipe.
± 5S±FE ENGINECOOLING SYSTEMEG1±245
Page 296 of 4770
7. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING
(a) Install the pulley with the bolt. Do not tighten the bolt
yet.
HINT: Use bolt 42 mm (1.65 in.) in length.
(b) Install the tension spring.
(c) Pry the pulley toward the left as far as it will go and
tighten the bolt.
(d) Check that the idler pulley moves smoothly.
8. INSTALL TIMING BELT (See page EG1±33)
9. CONNECT NEGATIVE (±) TERMINAL CABLE TO
BATTERY
10. FILL WITH ENGINE COOLANT
(See page EG1±241) 6. INSTALL NO.2 IDLER PULLEY
(a) Install the pulley with the bolt.
Torque: 42 N±m (425 kgf±cm, 31 ft±lbf)
HINT: Use a bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly. 4. INSTALL GENERATOR BELT ADJUSTING BAR
Temporarily install the adjusting bar with the bolt.
5. CONNECT LOWER RADIATOR HOSE TO WATER
INLET (f) Install the 2 nuts holding the water pump cover to the
water bypass pipe.
Torque: 8.8 N±m (90 kgf±cm, 78 in.±Ibf)
± 5S±FE ENGINECOOLING SYSTEMEG1±246
Page 298 of 4770

THERMOSTAT INSTALLATION
(See Components for Removal and Installation)
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the upper
side of the stud bolt, and insert the thermostat in the
water pump.
HINT: The jiggle valve may be set within 5of either
side of the prescribed position.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N±m (90 kgf±cm, 78in.±Ibf)
(c) Check the valve lift.
Valve rift:
8 mm (0.31 in.) or more at 95C (203F)
If the valve lift is not as specified, replace the thermo±
stat.
(d) Check that the valve spring is tight when the thermo±
stat is fully closed.
If not closed, replace the thermostat. (a) Immerse the thermostat in water and gradually heat
the water.
(b) Check the valve opening temperature.
Valve opening temperature:
80 ± 84C (176 ± 183F)
If the valve opening temperature is not as specified,
replace the thermostat.
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve
opening temperature.
± 5S±FE ENGINECOOLING SYSTEMEG1±248
Page 305 of 4770

RADIATOR ASSEMBLY
(See Components for Disassembly and Assembly)
1. A/T:
INSTALL OIL COOLER TO LOWER TANK
(a) Clean the 0±ring contact surface of the lower tank
and oil cooler.
(b) Install new 0±rings (1) to the oil cooler (2).
(c) Install the oil cooler with the 0±rings to the lower
tank (3).
(d) Install the plate washers (4) and nuts (5). Torque the
nuts.
Torque: 8.3 N±m (85 kgf±cm, 74 in.±lbf)
(e) Install the pipes (6).
Torque: 22 N±m (220 kgf±cm, 16 ft±lbf)
HINT: Face the pipes in the same direction as before
disassembly.4. A/T:
REMOVE OIL COOLER FROM LOWER TANK
(a) Remove the pipes.
HINT: Make a note of the direction to face the pipes.
(b) Remove the nuts and plate washers.
(c) Remove the oil cooler and 0±rings. 3. REMOVE TANKS AND O±RINGS
(a) Lightly tap the radiator hose inlet (or outlet) with a
soft±faced hammer and remove the tank.
(b) Remove the 0±ring. 2. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle
until stopped by the stopper bolt.
SST 09230±01010
± 5S±FE ENGINECOOLING SYSTEMEG1±255
Page 309 of 4770
(b) Place the radiator in position, and install the 2 upper
supports with the 2 bolts.
HINT: After installation, check that the rubber cushion
(A) of the support is not depressed.
Torque: 13 N±m (130 kgf±cm, 9 ft±lbf)
6. INSTALL RADIATOR AND ELECTRIC COOLING
FANS
(a) Place the 2 lower radiator supports in position on the
body. 4. A/T:
INSTALL A/T OIL COOLER HOSES
5. INSTALL RADIATOR LOWER HOSE
8. CONNECT ENGINE COOLANT RESERVOIR HOSE
9. CONNECT RADIATOR HOSES 7. A/T:
CONNECT OIL COOLER HOSES
± 5S±FE ENGINECOOLING SYSTEMEG1±259
Page 317 of 4770
SERVICE SPECIFICATIONS
SERVICE DATA
TORQUE SPECIFICATIONS
Valve opening temperature
Valve lift
Water bypass pipe x Water pump cover
Radiator oil cooler x Radiator lower tank Water pump x Water pump cover
No.2 idler pulley x Cylinder block Water inlet x Water pump coverRelief valve opening pressure
Water pump x Cylinder blockCylinder block x Drain plug
Water inlet x Water pump
Radiator oil cooler pipe
Radiator support boltElectric
cooling fanRotating amperage
Part tightened Radiator cap
Plate height Thermostat
Radiator
± 5S±FE ENGINECOOLING SYSTEMEG1±267
Page 320 of 4770
PREPARATION
SST (SPECIAL SERVICE TOOLS)
(09627±30010) Steering Sector Shaft Bushing
Replacer09226±10010 Crankshaft Front & Rear Bearing
Replacer
(09631±00020) Handle09616±30011 Steering Worm Bearing Adjusting
Screw Wrench
RECOMMENDED TOOLS
Oil pump oil seal
Oil pump oil seal 09620±30010 Steering Gear Box Replacer Set
09090±04000 Engine Sling Device
09200±00010 Engine Adjust Kit09032±00100 Oil Pan Seat Cutter
09905±00013 Snap Ring Pliers09228±06500 Oil Filter wrench
Precision straight edge
EQUIPMENT
Oil pressure gaugeFor suspending engineCrankshaft front oil seal
Torque wrenchOil pump pulley
Oil pump
± 5S±FE ENGINELUBRICATION SYSTEMEG1±270