Water Pump: Service and Repair

WATER PUMP ASSY (2ZZ-GE) (May, 2003)
REPLACEMENT
1. DRAIN COOLANT
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 3 bolts and nut, then remove the cylinder head cover No.2.





4. REMOVE WIRE HARNESS PROTECTOR
(a) Unfasten the 3 clips, then remove the wire harness protector.
(b) Disconnect the pressure sensor connector.

5. REMOVE AIR SWITCHING VALVE ASSY





6. SEPARATE SUCTION HOSE SUB-ASSY
(a) Remove the 2 nuts, then separate the suction hose.





7. REMOVE FAN AND GENERATOR V BELT
(a) Slowly turn the V-ribbed belt tensioner clockwise, then remove the V belt.
8. REMOVE GENERATOR BRACKET NO.1
9. REMOVE GENERATOR ASSY





10. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)





11. REMOVE WATER PUMP ASSY
(a) Remove the 6 bolts and water pump.
(b) Remove the O-ring from the timing chain cover.





12. INSTALL WATER PUMP ASSY
(a) Place a new 0-ring on the timing chain cover.
(b) Install the water pump with the 6 bolts.
Torque: 9.0 N-m (92 kgf-cm, 80 in-lbf)





HINT: Each bolt length is indicated in the table.





13. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
Torque: 15 N-m (153 kgf-cm, 11 ft-lbf)

14. INSTALL GENERATOR ASSY
15. INSTALL GENERATOR BRACKET NO.1





16. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)
17. INSTALL AIR SWITCHING VALVE ASSY
18. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 N-m (71 kgf-cm, 62 in.-lbf)
19. ADD COOLANT
20. CHECK FOR ENGINE COOLANT LEAKS