Toyota 4Runner 2001-06

Removal & Installation

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1GR-FE Engine



  1. Drain the engine coolant.
  2.  
  3. Remove the engine under cover.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the upper radiator support seal by disconnecting the 11 clips.
  8.  
  9. Remove the accessory drive belt.
  10.  
  11. Remove the engine fan and fan pulley.
  12.  
  13. Remove the air intake assembly.
  14.  
  15. Disconnect the oil cooler hoses.
  16.  
  17. Disconnect the two radiator hoses.
  18.  
  19. Disconnect the five coolant by-pass hoses.
  20.  
  21. Remove the mounting bolts and remove the water inlet.
  22.  
  23. Remove the O-ring from the coolant outlet pipe.
  24.  
  25. Remove the gasket from the water pump.
  26.  
  27. Remove the two idler pulleys.
  28.  
  29. Remove the alternator.
  30.  
  31. Remove the A/C compressor mounting bolts and hang securely from the engine. Do not disconnect the refrigerant lines.
  32.  
  33. Remove the accessory drive belt tensioner.
    NOTE
    Keep the tensioner mounting bolts in order as they are different sizes.

  34.  
  35. Remove the water pump and gasket.

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    Fig. Disconnect the two oil cooler hoses from the water inlet-4.0L (1GR-FE) Engine



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    Fig. Disconnect the five water bypass hoses from the water inlet-4.0L (1GR-FE) Engine



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    Fig. After disconnecting the coolant hoses from the water inlet, remove the mounting bolts and remove the water inlet-4.0L (1GR-FE) Engine



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    Fig. Water pump mounting bolts-4.0L (1GR-FE) Engine

  36.  

To install:

  1. Install the water pump with a new gasket. There is no torque sequence, but tighten the bolts evenly in several passes. Torque the bolts with 0.39 inch (10 mm) heads to 80 inch lbs. and torque the bolts with 0.47 (12 mm) heads to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the accessory drive belt tensioner. Tighten the mounting bolts to 27 ft. lbs. (36 Nm).
  4.  
  5. Before installing the water inlet, apply a new gasket to the water pump mating surface and new O-ring to the water outlet pipe. Coat the O-ring in soapy water to aid in the installation of the water inlet.
  6.  
  7. Install the water inlet and tighten the mounting bolts to 80 inch lbs. (9 Nm).
  8.  
  9. Connect the five coolant bypass hoses, two radiator hoses and two oil cooler hoses to the water inlet.
  10.  
  11. Install the air intake assembly.
  12.  
  13. Install the fan pulley and engine fan.
  14.  
  15. Install the accessory drive belt.
  16.  
  17. Connect the 11 clips to install the upper radiator support seal.
  18.  
  19. Install the engine appearance cover.
  20.  
  21. Install the engine under cover. Tighten the bolts to 21 ft. lbs. (29 Nm).
  22.  
  23. Refill the cooling system to the correct level.
  24.  
  25. Start the engine and check for leaks.
  26.  

2UZ-FE Engine




WARNING
This procedure requires the removal of the timing belt. This is an extensive procedure requiring precision work, particularly at assembly. For additional information, please refer to the following topic(s): -Timing Belt Removal and Installation.- Do NOT attempt to remove the belt without consulting the procedure; extreme engine damage may occur.



Click image to see an enlarged view

Fig. Water pump and related components-4.7L (2UZ-FE) Engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the timing belt. For additional information, please refer to the following topic(s): -Timing Belt and Sprockets, Removal and Installation.-
  6.  
  7. Remove the No. 2 idler pulley.
  8.  
  9. Remove the water inlet and thermostat.
  10.  
  11. Remove the five bolts, two stud bolts and nut and separate the water pump from the engine block. Discard the gasket.
  12.  

To install:

  1. Installation is the reverse of the removal procedure. Clean all parts well. It is good practice to carefully clean all threaded openings, especially those exposed to coolant to remove rust and scale so at assembly, an accurate torque reading is obtained. Remove any old gasket material from the pump and mounting area of the engine using a razor blade and/or gasket scraper. Use care not to gouge aluminum parts.
  2.  
  3. Inspect the pump. Check the air hole (vent) and water holes for coolant leakage. If coolant has been leaking on the timing belt, replace the timing belt. Turn the pump pulley and check that the water pump bearing moves smoothly and quietly. If not, replace the water pump. Check the fan coupling (sometime called the fan clutch). It contains silicone oil. If it is leaking, it must be replaced.
  4.  
  5. Install a new O-ring to the water bypass pipe end. Lubricate with soapy water and connect the water pump to the water bypass pipe end. Using a new gasket, install the water pump. Uniformly tighten the bolts, stud bolts and nut, in several passes. Final torque should be:
    1. Bolts-16 ft. lbs. (21 Nm)
    2.  
    3. Stud bolts and nut-13 ft. lbs. (18 Nm)

      Click image to see an enlarged view

      Fig. Install a new O-ring to the water bypass pipe end when installing the water pump-4.7L (2UZ-FE) Engine

    4.  

  6.  
  7. Install the water inlet and inlet housing assembly. Use FIPG material. Make sure all old sealer is cleaned off. Apply a 1 / 8 -bead of sealer and install immediately. Tighten the bolts to 13 ft. lbs. (18 Nm). Connect the water bypass hose.
  8.  
  9. Install the No. 2 idler pulley.
  10.  
  11. Install the timing belt.
  12.  
  13. Fill the engine with coolant, start the engine and check for leaks. When cool, recheck engine coolant level.
  14.  

3.4L Engine



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Thermostat
     
    No. 2 oil cooler hose from the water pump
     
    Water pump
     

  8.  
  9. Thoroughly clean the mating surfaces.
  10.  

To install:

  1. Apply sealant (PN 08826-00100) to the water pump.
    WARNING
    Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

  2.  
  3. Install or connect the following:

    Water pump. Tighten the bolts to 14 ft. lbs. (20 Nm).
     
    No. 2 oil cooler hose
     
    Thermostat
     
    Timing belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

5VZ-FE Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Thermostat
     
    No. 2 oil cooler hose from the water pump
     
    Water pump
     

  8.  
  9. Thoroughly clean the mating surfaces.
  10.  


    Click image to see an enlarged view

    Fig. Water pump installation-3.4L engine


To install:

  1. Apply sealant (PN 08826-00100) to the water pump.
  2.  


WARNING
Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

  1. Install or connect the following:

    Water pump. Tighten the bolts to 14 ft. lbs. (20 Nm).
     
    No. 2 oil cooler hose
     
    Thermostat
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  



Click image to see an enlarged view

Fig. The water pump is located on the front of the engine block, behind the timing cover



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Fig. Once the retainers are removed, pull the pump away from the block



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Fig. Scrape any remaining gasket material from the block before installing the new pump



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Fig. Water pump mounting bolt locations



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Fig. Front view of the water pump and thermostat housing


WARNING
This procedure requires the removal of the timing belt. This is an extensive procedure requiring precision work, particularly at assembly. For more information, refer to -Timing Belt Removal and Installation.- Do NOT attempt to remove the belt without consulting the procedure; extreme engine damage may occur.



Click image to see an enlarged view

Fig. Apply sealant to the areas shown



Click image to see an enlarged view

Fig. Exploded view of the water pump arrangement-3.4L (5VZ-FE) Engine

  1. Drain the cooling system.
  2.  
  3. Remove the timing belt. For additional information, please refer to the following topic(s): -Timing Belt Removal and Installation.-
  4.  
  5. Remove the idler pulley.
  6.  
  7. Remove the thermostat.
  8.  
  9. Disconnect the oil cooler hose from the pump.
  10.  
  11. Remove the seven bolts and the tension spring bracket and then remove the water pump.
  12.  

To install:

  1. Clean all parts well. It is good practice to carefully clean all threaded openings, especially those exposed to coolant to remove rust and scale so at assembly, an accurate torque reading is obtained. This is important, since no-gasket applications like this depend on even clamp loads from the fasteners to avoid distortion and leaks. Remove any old sealer (Toyota calls it -packing-) from the pump and mounting area of the engine. Keep oil off the mating areas.
  2.  
  3. Apply Formed-In-Place-Gasket® (FIPG) sealer to the pump-to-block mating surface and then tighten the bolts to 14 ft. lbs. (20 Nm).
    NOTE
    The parts must be installed within five minutes of application of the sealant. Otherwise you must remove and reapply the sealer.

  4.  
  5. Connect the oil cooler hose.
  6.  
  7. Install the thermostat with a new gasket.
  8.  
  9. Install the idler pulley.
  10.  
  11. Install the timing belt.
  12.  
  13. Install the drive belts and adjust the tension.
  14.  
  15. Refill the cooling system to the correct level.
  16.  
  17. Start the engine and check for leaks.
  18.  

 
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