Toyota 16100-28041
Water Pump

Before commencing the water pump removal process from the 2AZ-FE engine start by disconnecting the negative battery cable terminal along with waiting at least 90 seconds to avoid activating the Air Bag and seat belt pretensioners. The first procedure requires draining engine coolant and disconnecting the front fender apron seal RH and engine under cover RH before removing the fan & generator V belt. Next, remove the generator assembly. Special Service Tool: 09960-10010 09962-01000 enables the removal of 4 bolts that fasten the water pump pulley. Start by detaching the crankshaft position sensor clamp from the water pump before disconnection of the wire from its clamp bracket. Detach the 4 bolts alongside 2 nuts and clamp bracket from the components. To safely remove the water pump from its position between the cylinder block the technician must use a screwdriver to separate it but be mindful of causing any damage to either contact area.

Begin the water pump assembly installation by removing seal packing from the contact area before you apply a continuous string of seal packing (Part No. 08826-00080 or equivalent) utilizing standard 2.2 to 2.5mm (0.09 to 0.10in.) diameter seal diameter. The installation procedure needs the user to clean off oil residue from contact surfaces while parts must stay in place for no more than 3 minutes after applying the new seal packing material before required reapplication. To install the water pump and clamp bracket use 4 bolts combined with 2 nuts tightening them to reach 9.0 Nm (92 kgf-cm, 80 in-lbf). The crankshaft position sensor wire should be installed onto the clamp bracket which must be secured to the water pump using the clamp of the crankshaft position sensor. Use Special Service Tool: 09960-10010, 09962-01000, and 09963-00700 to mount the water pump pulley with 4 bolts before achieving a torque of 26 Nm (265 kgf-cm, 19 ft-lbf). The generator assembly installation should be followed by adding the fan and generator V belt before adding engine coolant. Connect the negative end of the cable and then check for coolant leakage and install both the engine under cover on the right-hand side and the front fender apron seal on the right-hand side. The procedure ends with initialization which becomes essential when the cable reconnects or disconnects from the negative (-) terminal.

Install the water pump and clamp bracket with the 4 bolts and 2 nuts, torquing to 9.0 Nm (92 kgf-cm, 80 inch lbs.), then reconnect the wire and clamp of the crankshaft position sensor.

Inspect for coolant leaks and install the engine under cover RH and the front fender apron seal RH.

First, drain the engine coolant.

Use Special Service Tool: 09960-10010, 09962-01000, and 09963-00700 to install it with 4 bolts, torqued to 26 Nm (265 kgf-cm, 19 ft-lbf).

The parts must be set within 3 minutes and assembled within 15 minutes; otherwise, the material must be removed and reapplied.

Install the engine mounting stay No. 2 RH, engine moving control rod, vane pump V belt, V belt No. 1, inspect drive belt tension, add engine coolant, check for engine coolant leaks, and reinstall the front wheel RH.

Use Special Service Tool: 09960-10010 (09962-01000, 09963-00700) with 4 bolts, torquing to 26 Nm (265 kgf-cm, 19 ft. lbs.).

Use Special Service Tool: 09960-10010 09962-01000 09963-00700 to install it with 4 bolts, torqued to 26 Nm (265 kgf-cm, 19 ft-lbf).

Ensure any old packing (FIPG) material is removed from the contact surface, then apply seal packing (Part No. 08826-00080 or equivalent) to the water pump, making sure to remove any oil from the contact surface.

Use Special Service Tool: 09960-10010 09962-01000 to remove the 4 bolts securing it.

Disconnect the crankshaft position sensor wire harness clamp.

Remove the No. 2 engine mounting stay, the engine moving control rod sub-assembly, and the No. 2 engine mounting bracket.

Connect the cable to the negative battery terminal, add coolant for the engine, and inspect for coolant leaks.

Install the water pump and bracket with the 4 bolts and 2 nuts, torquing to 9.0 Nm (92 kgf-cm, 80 inch lbs.), and reconnect the crankshaft position sensor wire harness clamp.

Take off the V-ribbed belt and the generator assembly.

Apply seal packing (Part No. 08826-00080 or equivalent).

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

Use a screwdriver to pry between the water pump and the cylinder block to remove the water pump, ensuring to tape the screwdriver tip beforehand to avoid damaging the contact surfaces of the water pump and cylinder block.

Install the water pump pulley using Special Service Tool: 09960-10010 (09962-01000, 09963-00700) with 4 bolts, torquing to 26 Nm (265 kgf-cm, 19 ft. lbs.).

Remove the generator assembly and the water pump pulley using Special Service Tool: 09960-10010 (09962-01000, 09963-00700) to take out 4 bolts and the pump pulley.

Ensure any old packing (FIPG) material is removed and apply seal packing.

Drain the engine coolant.

Install the drive belt, fill with engine coolant, start the engine to check for coolant leaks, and recheck the engine coolant level.

Remove any oil from the contact surface, and set the parts within 3 minutes after applying the seal packing; otherwise, the material must be removed and reapplied.

Remove the front suspension member reinforcement RH, fan and generator V belt, and generator assembly.

Part No. 08826-00100 or equivalent.

Use Special Service Tool: 09960-10010 (09962-01000, 09963-00600) to take out the 4 bolts and pump pulley, disconnect the crankshaft position sensor wire clamp and wire from the water pump, and remove the 4 bolts, 2 nuts, wire clamp, and water pump.

Detach the clamp of the crankshaft position sensor from the water pump, disconnect the wire from the clamp bracket, and remove the 4 bolts, 2 nuts, and clamp bracket. Carefully pry between the water pump and cylinder block to remove it, ensuring not to damage the contact surfaces.

Use a nozzle cut to a 2.2 to 2.5 mm (0.09 to 0.10 inch) opening and assemble parts within 5 minutes.

Install the water pump pulley using Special Service Tool: 09960-10010, 09962-01000, and 09963-00700 with 4 bolts, torquing to 26 Nm (265 kgf-cm, 19 ft-lbf).

Install the generator assembly, fan and generator V belt, engine mounting bracket No.2 RH, engine moving control rod with bracket, engine mounting stay No.2 RH, front fender apron seal RH, and front wheel RH.

Install the water pump and wire clamp with the 4 bolts and 2 nuts, torquing to 9 Nm (90 kgf-cm, 80 inch lbs.).

Add engine coolant and check for leaks.

Disconnect the crankshaft position sensor wire harness clamp.