Water Pump: Service and Repair

WATER PUMP

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE ENGINE UNDER COVER (for 2WD)
3. REMOVE ENGINE UNDER COVER (for 4WD)
4. REMOVE REAR ENGINE UNDER COVER LH (for 2WD)
5. REMOVE COOL AIR INTAKE DUCT SEAL
6. REMOVE ENGINE ROOM SIDE COVER LH
7. REMOVE V-BANK COVER SUB-ASSEMBLY
8. REMOVE NO. 1 AIR CLEANER INLET
9. DRAIN ENGINE COOLANT
10. DISCONNECT NO. 1 RADIATOR HOSE
11. DISCONNECT NO. 2 RADIATOR HOSE
12. REMOVE V-RIBBED BELT
13. REMOVE NO. 2 ENGINE COVER





(a) Remove the 3 nuts and engine harness cover (LH bank side).





(b) Remove the 3 nuts and cover.

14. REMOVE NO. 1 ENGINE COVER
15. REMOVE INJECTOR DRIVER
16. REMOVE WATER INLET





(a) Disconnect the 5 hoses.





(b) Remove the 4 bolts, nut and water inlet.





(c) Remove the water inlet housing gasket and water outlet pipe's O-ring.

17. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE
18. REMOVE DISCHARGE HOSE SUB-ASSEMBLY
19. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD)
20. REMOVE OIL FILTER BRACKET (for 4WD)
21. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)
22. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD)
23. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)





26. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 4 bolts and water pump pulley.





27. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump and gasket.

INSPECTION





1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the water hole for coolant leakage.
If leakage is found, replace the water pump assembly.
(b) Turn the pulley and check that the water pump bearing moves smoothly and quietly.
If necessary, replace the water pump assembly.

INSTALLATION





1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 16 bolts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
9.1 N*m (93 kgf*cm, 81 in.*lbf) for bolt B and C

NOTICE:
^ Be sure to replace the 2 bolts labeled C 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 bolt A.

2. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
3. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
4. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)





5. 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 N*m (214 kgf*cm, 15 ft.*lbf)

6. INSTALL WATER INLET





(a) Install a new gasket to the water inlet housing.
(b) Install a new O-ring to the water outlet pipe.





(c) Install the water inlet with the 4 bolts and nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE: Be careful not to allow the O-ring to get caught between other parts.





(d) Connect the 5 hoses.

7. INSTALL COOLER COMPRESSOR ASSEMBLY (for 2WD)
8. TEMPORARILY TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
9. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)
10. INSTALL OIL FILTER BRACKET (for 4WD)
11. TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
12. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
13. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
14. INSTALL INJECTOR DRIVER
15. INSTALL NO. 1 ENGINE COVER
16. INSTALL NO. 2 ENGINE COVER





(a) Install the cover with the 3 nuts.





(b) Install the engine wire harness cover with the 3 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

17. INSTALL V-RIBBED BELT
18. CONNECT NO. 2 RADIATOR HOSE
19. CONNECT NO. 1 RADIATOR HOSE
20. INSTALL NO. 1 AIR CLEANER INLET
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
22. ADD ENGINE COOLANT
23. INSPECT FOR ENGINE COOLANT LEAK
24. INSTALL V-BANK COVER SUB-ASSEMBLY
25. INSTALL ENGINE ROOM SIDE COVER LH
26. INSTALL COOL AIR INTAKE DUCT SEAL
27. INSTALL REAR ENGINE UNDER COVER LH (for 2WD)
28. INSTALL ENGINE UNDER COVER (for 2WD)
29. INSTALL ENGINE UNDER COVER (for 4WD)
30. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.