OEM 2004 Toyota RAV4 Water Pump

2004 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the water pump on 2004 Toyota RAV4?

  A: The first step for servicing or repairing the water pump requires draining the engine coolant while also removing the drive belt. The water pump removal requires Special Service Tool: 09960-10010 (09962-01000, 09963-00600) to remove four bolts and the pump pulley. Additionally, disconnect the crankshaft position sensor wire clamp and wire from the water pump, then remove the four bolts, two nuts, wire clamp and finally the water pump. Begin service on the water pump by manipulating a tool between its gap with the cylinder block to remove it while maintaining surface contact integrity. When installing the water pump remove all FIPG material with a razor blade and gasket scraper, fully clean all parts, and apply a non-residue solvent to both contacting surfaces. Use a piece of seal packing (Part No. 08826-00100 or equivalent) by cutting a 2.2 to 2.5 mm (0.09 to 0.10 inch) nozzle opening to apply to the water pump before assembly within 5 minutes. Fasten the water pump by securing the wire clamp and four bolts while tightening to 9.0 Nm (92 kgf-cm, 80 inch lbs.), afterwards connect the wire harness clamp and wire to the water pump. The pump pulley installation process can be carried out using Special Service Tool: 09960-10010 (09962-01000, 09963-00600) which requires torquing the 4 bolts to 26 Nm (265 kgf-cm, 19 ft. lbs.). Post installation, replace the drive belt before filling with engine coolant then start the engine to verify no coolant leaks exist followed by another engine coolant check.