OEM 2003 Toyota RAV4 Water Pump

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the water pump on 2003 Toyota RAV4?

  A: Engine coolant drainage together with drive belt removal follows as the first steps for water pump servicing and repair. The application of Special Service Tool: 09960-10010 (09962-01000, 09963-00600) allows for removal of the 4 bolts while simultaneously removing the pump pulley. The procedure starts with disconnecting both the crankshaft position sensor wire clamp and the water pump wire before proceeding to remove four bolts and two nuts and the wire clamp and water pump itself. Accessing the water pump requires gentle prying between its installation point on the cylinder block while maintaining the contact surface integrity. Installation requires removal of existing FIPG packing with a razor blade followed by a gasket scraper to clean components thoroughly. Non-residue solvent treatment should be used on both surfaces before applying new packaging. Seal packing (Part No. 08826-00100 or equivalent) requires cutting the nozzle to 2.2 - 2.5 mm (0.09 - 0.10 inch) opening before assembling components within 5 minutes. The water pump installation requires the attachment of 4 bolts and 2 nuts before torquing to 9 Nm (90 kgf-cm, 80 inch lbs.). After reattaching the crankshaft position sensor wire harness clamp and wire to the water pump, install the pump pulley with its 4 bolts using Special Service Tool: 09960-10010 (09962-01000, 09963-00600), torquing them to 26 Nm (265 kgf-cm, 19 ft. lbs.). The drive belt installation must be followed by a coolant addition procedure before engine startup to verify coolant leaks and ensure correct engine coolant quantity.