Toyota 16100-09201
Water Pump

A service or repair of the water pump begins by removing the timing belt from its position. Start by disconnecting the water bypass hose from the water inlet housing before removing its two securing bolts for the water pump. The next step requires the water inlet housing to be separated from its front water bypass joint following which you can extract water inlet housing and inlet. The service begins with water pump assembly removal which requires separation of the 5 bolts, 2 stud bolts and a nut until the water pump with gasket exits the system. The O-ring should be extracted from the water bypass pipe during this stage.

A safe method to remove the water pump assembly of the 2UZ-FE cooling system starts with disconnecting the negative battery cable followed by a 90-second delay of the SRS system. You must note that a few systems need system initialization steps when you reconnect. You must follow the relevant instructions to disconnect the timing belt first. The first step involves breaking the water by-pass hose seal from the inlet water housing before removing its two securing bolts along with freeing up the water inlet to extract the O-ring from the housing. Finish the job by extracting the water pump assembly through five bolts and two stud bolts as well as a nut while removing the pump and gasket together with the O-ring from the water by-pass pipe.

First install the water pump using 17 bolts with new gasket before torqueing both 10 mm head bolts to 9.0 Nm (92 kgf-cm, 80 in-lbf) and 12 mm head bolts to 23 Nm (235 kgf-cm, 17 ft-lbf). Secondly install the generator assembly before proceeding with the V-ribbed belt tensioner assembly. Installation of the No. 2 idler pulley sub-assembly relies on an idler pulley cover plate presence for different procedures. To install the cover plate (PU107013ARMXY3) you must first install the idler pulley as well as the No. 2 idler pulley cover plate and finally torque them to 54 Nm (551 kgf-cm, 40 ft-lbf). The installation of the idler pulley and No. 2 idler pulley cover plate should be performed with equal torque when the cover plate (PU107013ARMXY1) is not utilized. The replacement of any pulley or plate requires the entire set of new parts with the No. 2 idler pulley marked "PU107013ARMXY3." The procedure requires a new gasket placement between the water pump and water outlet pipe followed by A gasket lubrication with soapy water and subsequent tightening of five bolts to 9.0 Nm (92 kgf-cm, 80 in-lbf). You should connect the 5 water by-pass hoses alongside the 2 oil cooler hoses. Afterward install the fan shroud and connect both radiator hose inlets along with outlets and place the air cleaner assembly with its element hooking up the No. 2 air cleaner hose. Engine coolant addition should occur before installing the V-bank cover and No. 1 engine under cover while checking for any coolant leakage.

The water pump installation for 1GR-FE cooling should begin with applying new gaskets and bolts on the water pump with 9.0 Nm (92 kgf-cm, 80 in-lbf) torque for 10 mm head bolts and 23 Nm (235 kgf-cm, 17 ft-lbf) for 12 mm head bolts. Installation of generator assembly comes after the V-ribbed belt tensioner assembly. The No. 2 idler pulley sub-assembly must be installed by using 2 bolts to fasten the idler pulleys and cover plates and torquing them to 39 Nm (398 kgf-cm, 29 ft-lbf). The installation process for water inlet housing begins with two new gaskets placed on water outlet pipe and water pump followed by gasket section A lubrication with soapy water before installing five bolts with 9.0 Nm (92 kgf-cm, 80 in-lbf) torque. Attach the 5 water by-pass along with the 2 oil cooler hoses. Next install the air cleaner assembly along with element while attaching the No. 2 air cleaner hose and first connecting the radiator hose inlet and outlet. Engine coolant must be added to your system while you check for any coolant fluid leaks occurring. Conclude by mounting the V-bank cover and decorating the No. 1 engine under cover.

Tighten the bolts alternately to a torque of 18 Nm (185 kgf-cm, 13 ft-lbf).

Reinstall the V-ribbed belt tensioner assy, cooler compressor assy, and generator assy.

Remove the 4 fluid coupling nuts to take out the fan with fluid coupling and fan shroud together.

Unfasten the hose clamp to separate the 2 oil cooler hoses, disconnect the radiator reserve tank hose, and remove the 2 fan shroud bolts and radiator reserve tank bolt.

Reconnect the 5 water by-pass hoses, 2 radiator hoses, and 2 oil cooler hoses.

Disconnect the water bypass hose.

Check the fan bracket sub-assembly for smooth pulley operation and replace if needed.

Check the smoothness of the fan pulley and replace the pulley bracket if necessary, and inspect the timing belt components.

Ensure the water pump bearing moves smoothly and quietly when the pulley is turned, replacing the water pump if necessary.

Remove the 2 bolts securing the inlet water housing along with the water inlet, and take out the O-ring from the inlet water housing.

Remove the 2 bolts securing the water inlet housing to the water pump and detach it from the front water bypass joint, taking care to remove the O-ring.

Remove the timing belt, followed by the No.2 idler pulley.

Take out the bolt and idler pulley.

Place a new O-ring on the water bypass pipe end and apply soapy water to the O-ring.

Place a new O-ring on the water bypass pipe end, apply soapy water to it, and connect the water pump to the water bypass pipe. Install the water pump with a new gasket using the five bolts, two stud bolts, and nut, tightening them uniformly in several passes to the specified torque of 21 Nm for bolts and 18 Nm for stud bolts and nut.

Connect the water pump to the water by-pass pipe end, then temporarily install the water pump with a new gasket using 5 bolts, 2 stud bolts, and a nut.

Take out the 17 bolts, along with the water pump and gasket.

Install the water pump with the 7 bolts, torquing to 20 Nm (200 kgf-cm, 14 ft. lbs.).

Place a new O-ring on the water bypass pipe end, apply soapy water, connect the water pump to the water bypass pipe, and install the water pump with a new gasket using the 5 bolts, 2 stud bolts, and nut.

Inspect the fan pulley bracket for smooth turning and replace if needed, and check the timing belt components.

Take out the 17 bolts, the water pump, and the gasket.

Clean any old packing (FIPG) material from the water pump and cylinder block surfaces using a razor blade and gasket scraper, then clean with a non-residue solvent.

Turn the pulley to ensure the water pump bearing moves smoothly and quietly, replacing the assembly if necessary.

Inspect the water pump for coolant leakage at the air hole and water hole, and check that the water pump bearing moves smoothly; replace if necessary.

Install the oil dipstick and guide, using a new O-ring and applying soapy water to it before securing it to the generator bracket with the bolt, torqued to 8 Nm (80 kgf-cm, 70 inch lbs.).