Toyota 16100-29145
Water Pump

Proceed to service and repair the water pump by first removing the RH engine under cover together with draining engine coolant before you remove the drive belt. A 1ZZ-FE machine requires six bolt removal to disconnect the water pump as well as its O-ring from another bolt followed by water chamber room cleaning from all engine coolant. Special Service Tool: 09960-10010 (09962-01000, 09963-00600) must be utilized to remove the 4 water pump pulley set bolts followed by the water pump pulley and subsequent removal of the 6 bolts and water pump then O-ring and ensure complete removal of coolant from the water chamber room. The proper water pump replacement requires users to avoid removing the RH engine mounting bracket or generator from installation. The water pump must be checked for drain hole coolant leakages and bearing movement before the replacement decision. The installation process for the 1ZZ-FE engine requires a new O-ring on the timing chain cover followed by water pump installation with 6 bolts and torque values of Bolt A to 9.0 Nm (92 kgf-cm, 80 inch lbs.) and Bolt B to 11 Nm (113 kgf-cm, 8 ft. lbs.) with measurements of Bolt A being 30 mm (1.18 inch) and Bolt B measuring 35 mm (1.38 inch). The installation of the water pump with 6 bolts on 2ZZ-GE requires placing a new O-ring on the timing chain cover and applying torque to 9.0 Nm (92 kgf-cm, 80 inch lbs.). Next install the water pump pulley then tighten the 4 water pump pulley set bolts to 15 Nm (153 kgf-cm, 11 ft. lbs.) using Special Service Tool: 09960-10010 (09962-01000, 09963-00600). After reinstalling the RH engine under cover, drive belt, the system requires filling with engine coolant and engine operation to detect leaks and recheck engine coolant levels.

Before beginning the water pump replacement procedure workers must remove the engine under cover on the right-hand side and drain all coolant. After disconnecting the wire clamp from the wire clip located on the rectifier end frame the process requires removing the rubber cap and nut which disconnects the alternator wire. Then disconnect the alternator connector and remove the two bolts to extract the alternator. Utilize Special Service Tool: 09960-10010 (09962-01000, 09963-00600) to disassemble the four bolts and water pump pulley followed by the removal of the six bolts, water pump along with the O-ring. Install a fresh O-ring on the timing chain cover before installing the water pump through its 6 bolts while torqueing to 9.0 Nm (150 kgf-cm, 80 inch lbs.). Special Service Tool: 09960-10010 (09962-01000, 09963-00600) is required for installing the water pump pulley which requires 15 Nm (153 kgf-cm, 11 ft. lbs.) torque. Reassemble the generator while torquing the 12mm head to 25Nm (250kgf-cm, 118ft.lb) and the 14mm head to 54Nm (550kgf-cm, 39ft.lb). The last step involves adding coolant followed by leak inspection of the engine coolant system.

Remove the RH engine under cover, drain the engine coolant, and remove the drive belt.

Special Service Tool: 09960-10010 (09962-01000, 09963-00600).

Install the water pump with the 6 bolts, applying a torque of 9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt A and 11 Nm (112 kgf-cm, 8 ft. lbs.) for bolt B.

Place a new O-ring on the timing chain cover, install the water pump with the 6 bolts, torquing Bolt A to 9.0 Nm and Bolt B to 11 Nm.