Water Pump: Installation

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL WATER PUMP
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the water pump and cylinder block.
  - Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves.
  - Thoroughly clean all components to remove all the loose material.
  - Using a non-residue solvent, clean both sealing surfaces.
2. Apply seal packing to the water pump as shown in Fig 1.
  Seal packing: Part No. 08826-00100 or equivalent
  - Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening.
  - Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
  - Immediately remove nozzle from the tube and reinstall cap.
    
    Fig 1: Applying Seal Packing To Water Pump
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the water pump and wire clamp with the 4 bolts and 2 nuts.
  
  Fig 2: Installing Water Pump & Wire Clamp With 4 Bolts & 2 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
4. Install the crankshaft position sensor wire harness clamp to the water pump.
5. Install the crankshaft position sensor wire to the wire clamp on the water pump.
6. Using SST, install the pump pulley with the 4 bolts.
  SST 09960-10010 (09962-01000, 09963-00600)
  
  Fig 3: Installing Water Pump Pulley & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
INSTALL DRIVE BELT (See ON-VEHICLE TESTING )
FILL WITH ENGINE COOLANT
START ENGINE AND CHECK FOR COOLANT LEAKS
RECHECK ENGINE COOLANT LEVEL