Water pump assy (2AZ−FE)(From July, 2003)

1. 1
   DRAIN ENGINE COOLANT
2. 2
   REMOVE FRONT WHEEL RH
3. 3
   REMOVE FRONT FENDER APRON SEAL RH
4. 4
   REMOVE ENGINE MOVING CONTROL ROD W/BRACKET
5. 5
   REMOVE ENGINE MOUNTING STAY No.2 RH
6. 6
   REMOVE ENGINE MOUNTING BRACKET No.2 RH
7. 7
   REMOVE FAN AND GENERATOR V BELT
8. 8
   REMOVE GENERATOR ASSY
9. 9
   REMOVE WATER PUMP PULLEY
10. 10

    Using SST, remove the 4 bolts and pump pulley.

    SST 09960−10010 (09962−01000, 09963−00700)

11. 11

    Disconnect the crankshaft position wire harness clamp.

a. Remove the 4 bolts, 2 nuts, bracket and water pump.

a. 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.

HINT:

• 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 loose material.

• Using a non−residue solvent, clean both sealing surfaces.

b. Apply seal packing to the water pump as shown in the illustration.

HINT:

• 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 the nozzle from the tube and reinstall cap.

1. 1

   Install the water pump and bracket with the 4 bolts and 2 nuts.

   Torque: 9 N·m
2. 2

   Connect the crankshaft position wire harness clamp.

   

a. Using SST, install the pump pulley with the 4 bolts.

1. 1
   INSTALL GENERATOR ASSY
2. 2
   INSTALL FAN AND GENERATOR V BELT
3. 3
   INSTALL ENGINE MOUNTING BRACKET No.2 RH
4. 4
   INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
5. 5
   INSTALL ENGINE MOUNTING STAY No.2 RH
6. 6
   INSTALL FRONT FENDER APRON SEAL RH
7. 7
   INSTALL FRONT WHEEL RH
8. 8
   ADD ENGINE COOLANT
9. 9
   CHECK FOR ENGINE COOLANT LE