Toyota 16100-09442
Water Pump

The process of extracting the water pump for the 2GR-FE engine begins with draining engine coolant followed by front wheel RH removal along with engine under cover RH. The first step includes taking off the V-bank cover sub-assembly and the engine moving control rod together with the engine mounting control bracket and engine mounting bracket front No.1 LH. The fan and generator V belt needs removal followed by releasing the radiator hose outlet. The water pump removal procedure includes disconnecting the water hose before extracting the 2 bolts, nut and water inlet housing which also removes the water inlet housing gasket No.1 and water outlet pipe O-ring. The procedure first requires removal of the crankshaft pulley with Special Service Tools 09213-70020 and 09213-70011 followed by usage of Special Service Tools 09960-10010, 09962-01000, and 09963-00700 to hold the water pump pulley while taking out its 4 bolts and pulley. The technician should first detach the sub-assembly of idler pulley No.2 by removing the bolt and idler pulley cover plate No.2 along with idler pulley sub-assembly No.2 while being careful about the left-hand threaded bolt. To complete the process separate the vane pump assembly followed by removing the water pump assembly through sixteenth bolt removal while also taking out the water pump assembly and water pump gasket.

The installation of 2AZ-FE cooling system water pump assembly starts by removing all existing seal packing from contact surfaces then applying a continuous Black Toyota Genuine Seal Packing or Three Bond 1207B or similar to achieve a standard 2.2 to 2.5 mm (0.09 to 0.10 in.) diameter. The parts should be placed within a three-minute window after seal packing application. Any delayed installation will require removal of the material and reapplication. Fit the water pump and clamp bracket through four bolts and two nuts while tightening them to 9.0 Nm (92 kgf-cm, 80 in-lbf). The water pump receiving wire from the crankshaft position sensor must be installed on the clamp bracket before securing the clamp around the pump. To install the water pump pulley mount it with 4 bolts using Special Service Tool: 09960-10010 09962-01000 09963-00700 while torquing bolts to 26 Nm (265 kgf-cm, 19 ft-lbf). Add the generator assembly followed by V-ribbed belt and the No. 2 engine mounting bracket RH and engine moving control rod sub-assembly and the No. 2 engine mounting stay RH. Gather the cable from the negative terminal then hook it onto the battery while filling the engine with coolant and verifying for any fluid leakage. The installation process should conclude with the engine under cover on both LH and RH sides and front wheel opening extension pads on both RH and LH sides.

The installation of the 2AZ-FXE cooling system water pump requires removing existing packing material from the contact surfaces then applying Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent along a regular diameter of 2.2 to 2.5 mm (0.09 to 0.10 in.). The contact surface requires complete oil removal before the installation within three minutes after seal packing because delayed procedures will need new material application. The water pump receives installation together with its clamp bracket through four bolts and two nuts, while torquing to the specified 9.0 Nm providing 92 kgf-cm or 80 in-lbf torque values. Secure the clamp of the crankshaft position sensor onto the water pump after wiring it to the clamp bracket. The water pump pulley installation requires Special Service Tools 09960-10010 09962-01000 09963-00700 for its 4-bolt assembly that needs torquing to 26 Nm (265 kgf-cm, 19 ft-lbf). The next step includes sequencing the V-ribbed belt tensioner assembly with the V-ribbed belt along with the V-ribbed belt tensioner cover sub-assembly. The workshop should first install the No. 2 engine mounting bracket RH along with the engine moving control rod sub-assembly and No. 2 engine mounting stay RH. Complete the battery cable connection at the negative terminal then fuel the engine with fluid while checking the entire system for leakage. To complete the exhaust system installation the technician must fit the engine under cover LH and RH followed by front wheel opening extension pads RH and LH.

As a first step for water pump assembly installation onto 2AZ-FE cooling system start by cleaning the contact surfaces from previous packing material before extending a continuous line of Toyota Genuine Seal Packing Black or Three Bond 1207B or equivalent to a standard 2.2 to 2.5 mm (0.09 to 0.10 in.) diameter. Set assembly parts within three minutes after packing application. The parts need to rest on their seats not later than three minutes after placement of new seal packing or the process requires removal. Position the water pump along with its clamp bracket by using 4 bolts and 2 nuts which require 9.0 Nm (92 kgf-cm, 80 in-lbf) tightening torque. The crankshaft position sensor wire installation begins with attaching it to the clamp bracket followed by connecting the clamp of the crankshaft position sensor to the water pump. Special Service Tools 09960-10010 09962-01000 09963-00700 should be used to install the water pump pulley through four bolts with a torque setting at 26 Nm (265 kgf-cm, 19 ft-lbf). Connector the generator assembly while also installing the fan with the generator V belt together with the front suspension member reinforcement RH. Safely attach the cable to the negative battery terminal while adding engine coolant for leak inspection. To finish the task install the radiator support opening cover with the front fender apron RH along with the No. 1 engine under cover.

Begin water pump installation by applying a fresh gasket onto the assembly followed by its installation with 16 bolts. Torque Bolt A to 21 Nm (214 kgf-cm, 15ft-lbf) and Bolts B and C to 11 Nm (112 kgf-cm, 8ft-lbf), while avoiding oil on Bolt A threads and replacing C bolts with new ones or implementing adhesive 1344. The approved adhesives include Toyota Genuine Adhesive 1344, Three Bond 1344, or an equivalent. Attach the water inlet housing with 2 bolts and a nut according to a torque of 10 Nm (102 kgf-cm, 7ft-lbf) while being careful to avoid damaging the O-ring during installation. Use Special Service Tools 09960-10010, 09962-01000 and 09963-00700 to hold the pulley before tightening its 4 bolts to 21 Nm (214 kgf-cm, 15ft-lbf). Start by installing 5 bolts into the V-ribbed belt tensioner assembly and torque them to 43 Nm (438 kgf-cm, 32ft-lbf), then proceed with installing 2 idler pulley cover plates and 2 No. 2 idler pulley cover plates and 2 No. 2 idler pulley sub-assemblies using 2 bolts which reach 54 Nm (550 kgf-cm, 40ft-lbf) torque. Remember the diameter measurements of 33.6 mm (1.32 in.) for the idler pulley cover plate and 37 First mount the No. 1 engine front bracket LH to the front of the engine and place the generator assembly as well as the compressor and magnetic clutch units before adding the engine hangers. After removing the engine stand install the engine assembly and transaxle. The last task involves adding coolant before conducting a leak inspection of the system.

The beginning process of water pump removal consists of disconnecting the negative battery cable followed by potential system initialization procedures after restoring the cable connection. Begin by taking off the sub-assembly of the No. 1 engine cover followed by removal of the cool air intake duct seal and the No. 1 engine under cover and the No. 2 engine under cover. First drain engine coolant and proceed to remove the V-ribbed belt. The first step requires removing the wire harness clamp bracket followed immediately by the generator assembly. After pulling out the V-ribbed belt tensioner assembly and water pump assembly you must remove its 7 bolts together with the water pump and water pump gasket.

Remove the front wheel RH and the engine under cover RH.

Ensure there is no oil on the threads of the A bolts.

Detach the clamp of the crankshaft position sensor, disconnect the wire from the clamp bracket, and remove the 4 bolts, 2 nuts, and clamp bracket.

Remove the water inlet housing gasket No.1 and water outlet pipe O-ring.

Use Special Service Tool: 09213-70011 (09213-70020), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) to remove the crankshaft pulley.

Remove the front wheel opening extension pads on both the right and left sides, followed by the engine under covers on both sides.

Remove the V-ribbed belt and the generator assembly.

Remove the front fender apron seal on the right side.

Use Special Service Tool: 09960-10010, 09962-01000, and 09963-00700 to hold the pulley.

Disconnect the cable from the negative battery terminal and wait at least 90 seconds to disable the SRS system.

Inspect for coolant leakage at the drain hole and check that the bearing moves smoothly without noise; replace the assembly if necessary.

Install the V-ribbed belt tensioner assembly.

Disconnect the cable from the negative battery terminal and wait at least 90 seconds to prevent airbag and seat belt pretensioner activation.

The V-ribbed belt tensioner assembly should be installed with 5 bolts, torqued to 43 Nm (438 kgf-cm, 32 ft-lbf).

Remove the water pump assembly by taking out the 16 bolts, the assembly, and the water pump gasket.

Install the No. 1 engine under cover.

Ensure no oil is on the threads of bolt A.

Torque to 9.0 Nm (92 kgf-cm, 80 inch lbs.).