Toyota 16100-29085
Water Pump

Draining engine coolant must be your first step when servicing the water pump. Begin the water pump service by removing the front wheel RH as well as the front fender apron seal RH, engine moving control rod with bracket, engine mounting stay No.2 RH, then engine mounting bracket No.2 RH. The service begins by eliminating the fan and generator V belt then proceeding to remove the generator assembly. Special Service Tool 09960-10010 (or 09962-01000, 09963-00700) supports the removal of water pump pulley by disconnecting four bolts to release the pulley and unclamping the crankshaft position sensor wire harness. Begin the process by removing the water pump assembly through the steps of extracting its 4 bolts in addition to 2 nuts bracket and water pump. Check the water pump assembly for coolant drips from drainage holes and air valve holes while verifying the bearing movement until you fix or replace the assembly. The first step for installation includes using a gasket scraper and razor blade to remove all old FIPG packing from the gasket surfaces and sealing grooves while cleaning components thoroughly with non-residue solvent. Install Toyota Genuine Seal Packing Black or Three Bond 1207B seal packing or equivalent through a nozzle with 2.2 to 2.5 mm (0.087 to 0.098 inches) opening before part assembly within five minutes. The water pump assembly needs to be installed together with its bracket by tightening 4 bolts and 2 nuts to 9.0 Nm (92 kgf-cm, 80 inch lbs.). Then reattach the crankshaft position sensor wire harness clamp. The water pump pulley gets its installation with 4 bolts using Special Service Tool: 09960-10010 (09962-01000, 09963-00700) when the torque reaches 26 Nm (265 kgf-cm, 19 ft. lbs.). The generator assembly and fan along with the generator V belt should be installed followed by engine mounting bracket No.2 RH plus engine moving control rod with bracket and engine mounting stay No.2 RH and front fender apron seal RH and front wheel RH. The procedure ends with coolant addition while searching for coolant leakage points.

The first step to install the 2AZ-FE cooling system water pump assembly involves cleaning all gasket surfaces because FIPG packing material needs removal without allowing oil contact between the pump and cylinder block. A razor blade combined with a gasket scraper must scrape away all original packing materials from gasket areas and sealing channels before cleaning all elements thoroughly while using non-residue solvents to clean both contact surfaces. Tools need to use a nozzle opening size of 2.2 to 2.5 mm (0.09 to 0.10 in.) for water pump seal packing (Part No. 08826-00080 or equivalent) application. Parts must be assembled within a 5-minute time frame; otherwise, remove the material and reapply it. Place the sealing tube in the water pump before immediately removing the nozzle then fixing the cap. Use 4 bolts and 2 nuts to fasten the water pump along with its bracket and torque them to 9.0 Nm (92 kgf-cm, 80 in-lbf). Then install the crankshaft position sensor wire harness clamp. Using Special Service Tools 09960-10010 and 09962-01000 and 09963-00700 you should install the water pump pulley with four bolts that require 26 Nm torque. The next part of installation includes mounting the generator assembly as well as installing the fan and generator V belt and engine mounting bracket No.2 RH together with the engine moving control rod with bracket and engine mounting stay No.2 RH and front fender apron seal RH and front wheel RH. After completing engine coolant addition you must check for coolant leakages.

A water pump service or repair requires the draining of engine coolant during the first step. The service and repair of the water pump begins with removing the outer front cowl top panel assembly and following it with the timing belt along with camshaft timing pulleys and No.2 idler pulley and finally the No.3 timing belt cover. The installation requires removing the water pump by unbolting its four fixtures together with two nuts and the gasket and pump separately. The drain hole of the water pump should be examined visually for coolant leaks during inspection. Replace the water pump if any leakage is present. Inspection requires a pulley rotation check for the smooth operation of the water pump bearing along with necessary water pump replacement. Examine all components belonging to the timing belt system. Align a new gasket along with the water pump before mounting it into place via the 4 bolts and 2 nuts while applying torque to 6 Nm (60 kgf-cm, 53 inch lbs.) and avoiding gasket contact with oil. After installing the No.3 timing belt cover proceed to install the No.2 idler pulley along with the camshaft timing pulleys and timing belt before you complete the installation with the outer front cowl top panel assembly. Perform the first start-up by adding engine coolant then inspect for any leakage while verifying the engine coolant reading.

Place a new gasket and the water pump with the 4 bolts and 2 nuts, torquing to 8.0 Nm (82 kgf-cm, 71 inch lbs.).

Remove the timing belt, camshaft timing pulleys, No.2 idler pulley, and No.3 timing belt cover.

Install with 4 bolts and 2 nuts, torquing to 9.0 Nm (92 kgf-cm, 80 inch lbs.).

Take out the water pump by removing the 4 bolts and 2 nuts along with the gasket.

Inspect the timing belt components as well.

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.).

Place a new gasket and the water pump back in position using the 4 bolts and 2 nuts, torquing to 8 Nm (80 kgf-cm, 69 inch lbs.), ensuring no oil contacts the gasket.

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

Take off the 2 nuts securing the water pump to the water bypass pipe and the 3 bolts in the specified sequence. Disconnect the water pump cover from the water bypass pipe and remove the assembly along with the gasket and 2 O-rings.

Ensure to remove any old packing (FIPG) material without spilling oil on the contacting surfaces, using a razor blade and gasket scraper to clean all surfaces thoroughly with a non-residue solvent.

Install the water pump within 5 minutes and avoid putting engine oil in for 2 hours post-installation.

Remove the water pump assembly by taking out 4 bolts, 2 nuts, and the bracket.

Reinstall 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, front wheel RH, add engine coolant, and check for any engine coolant leakage.

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.).

First, remove the engine assembly with the transaxle.

Visually check the drain hole for coolant leakage and turn the pulley to ensure the water pump bearing moves smoothly and quietly.

Install the generator assembly.

Remove the front wheel RH, front wiper arm head cap, front wiper arms RH and LH, cowl top ventilator louver sub-assembly, wiper link assembly, No. 1 cowl top cowl brace inner, cowl top panel sub-assembly outer front, front fender apron seal RH, No. 1 V belt, vane pump V belt, engine moving control rod, engine mounting stay No. 2 RH, No. 2 generator bracket, crankshaft pulley, timing belt No. 1 cover, timing belt No. 2 cover, engine mounting bracket RH, No. 2 timing belt guide, timing belt, No. 2 timing belt idler sub-assembly, camshaft timing pulley, timing belt No. 3 cover, and No. 1 timing belt idler sub-assembly.

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

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

Remove the front wheel RH, front wiper arm head cap, front wiper arms RH and LH, cowl top ventilator louver sub-assembly, wiper link assembly, cowl top to cowl brace inner No.1, cowl top panel sub-assembly outer front, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No.1, vane pump V belt, engine moving control rod, engine mounting stay No.2 RH, generator bracket No.2, and crankshaft pulley using specified Special Service Tools.

Remove the front wheel RH, front wiper arm head cap, front wiper arms RH and LH, cowl top ventilator louver sub-assembly, wiper link assembly, cowl top to cowl brace inner No.1, cowl top panel sub-assembly outer front, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No.1, vane pump V belt, engine moving control rod, engine mounting stay No.2 RH, generator bracket No.2, and crankshaft pulley using Special Service Tools.

Place a new gasket and the water pump back in position using the 4 bolts and 2 nuts, torquing to 6 Nm (60 kgf-cm, 53 inch lb.), ensuring no oil contacts the gasket.

Remove the generator assembly.

Remove the outer front cowl top panel assembly, timing belt, camshaft timing pulleys, No.2 idler pulley, and No.3 timing belt cover.

Apply seal packing (Part No. 08826-00080 or equivalent) to the water pump, ensuring the nozzle is cut to a 2.2 to 2.5 mm (0.09 to 0.10 inch) opening, and assemble parts within 5 minutes of application.

Use Special Service Tool: 09960-10010 (09962-01000, 09963-00700) to remove the 4 bolts and pump pulley, and disconnect the crankshaft position sensor wire harness clamp.