Toyota RAV4 2000-05

Removal & Installation

Print



Click image to see an enlarged view

Fig. Exploded view of the water pump and related components-RAV4

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand engine undercover
     

  4.  
  5. Drain the engine coolant from the radiator and engine.
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Lower radiator hose from the water inlet
     
    Timing belt tension spring and the No. 2 idler pulley
     
    Crankshaft Position (CKP) sensor connector clamp
     
    Alternator drive belt adjusting bar
     
    2 water pump-to-water bypass pipe nuts
     
    3 water pump bolts in the sequence

    Click image to see an enlarged view

    Fig. Loosening sequence for the water pump bolts-RAV4

     



    Water pump cover from the water bypass pipe
     
    Water pump and water pump cover assembly
     
    Gasket and 2 O-rings from the water pump and water bypass pipe
     
    3 bolts, water pump and gasket, from the water pump cover
     

  8.  

To install:

  1. Install or connect the following:

    Water pump to the water pump cover, using a new gasket. Tighten the 3 bolts to 78 inch lbs. (9 Nm).
     
    New O-ring and gasket to the water pump cover
     
    New O-ring to the water bypass pipe, by applying soapy water to the O-ring
     
    Water pump cover to the water bypass pipe; do not install the nuts at this time
     
    Water pump. Tighten the 3 bolts, in sequence, to 78 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Tightening sequence for the water pump bolts-RAV4

     



    Water pump cover to the water pump pipe. Tighten the 2 bolts to 82 inch lbs. (9 Nm).
     
    Alternator drive belt adjusting bar. Tighten the bolt to 20 ft. lbs. (27 Nm).
     
    CKP connector clamp
     
    No. 2 idler pulley and timing belt tension spring
     
    Lower radiator hose
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. Fill the engine and radiator with engine coolant.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Install the right-hand engine undercover.
  8.  

2.0L Engine





Click image to see an enlarged view

Fig. Exploded view of the water pump and related components-2.0L

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand engine undercover
     

  4.  
  5. Drain the engine coolant from the radiator and engine.
  6.  
  7. Remove or disconnect the following:

    Drive belt
     
    Lower radiator hose from the water inlet
     
    Drive belt tension spring and the No. 2 idler pulley
     
    Crankshaft Position (CKP) sensor connector clamp
     
    Alternator drive belt adjusting bar
     
    2 water pump-to-water bypass pipe nuts
     
    3 water pump bolts in the sequence
     



    Click image to see an enlarged view

    Fig. Loosening sequence for the water pump bolts-2.0L engine



    Water pump cover from the water bypass pipe
     
    Water pump and water pump cover assembly
     
    Gasket and 2 O-rings from the water pump and water bypass pipe
     
    3 bolts, water pump and gasket, from the water pump cover
     

  8.  

To install:

  1. Install or connect the following:

    Water pump to the water pump cover, using a new gasket. Tighten the 3 bolts to 78 inch lbs. (9 Nm).
     
    New O-ring and gasket to the water pump cover
     
    New O-ring to the water bypass pipe, by applying soapy water to the O-ring
     
    Water pump cover to the water bypass pipe; do not install the nuts at this time
     
    Water pump. Tighten the 3 bolts, in sequence, to 78 inch lbs. (9 Nm).
     



    Click image to see an enlarged view

    Fig. Tightening sequence for the water pump bolts-2.0L engine



    Water pump cover to the water pump pipe. Tighten the 2 bolts to 82 inch lbs. (9 Nm).
     
    Alternator drive belt adjusting bar. Tighten the bolt to 20 ft. lbs. (27 Nm).
     
    CKP connector clamp
     
    No. 2 idler pulley and drive belt tension spring
     
    Lower radiator hose
     
    Drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the engine and radiator with engine coolant.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Install the right-hand engine undercover.
  8.  



Click image to see an enlarged view

Fig. Water pump and related components-2.0L

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right side engine undercover
     

  4.  
  5. Drain the engine coolant from the radiator and engine.
  6.  
  7. Remove or disconnect the following:

    Drive belt
     
    Lower radiator hose from the water inlet
     
    Drive belt tension spring and the No. 2 idler pulley
     
    Crankshaft Position (CKP) sensor connector clamp
     
    Alternator drive belt adjusting bar
     
    2 water pump-to-water bypass pipe nuts
     
    3 water pump bolts in the sequence

    Click image to see an enlarged view

    Fig. Water pump bolt loosening sequences-2.0L engine

     



    Water pump cover from the water bypass pipe
     
    Water pump and water pump cover assembly
     
    Gasket and 2 O-rings from the water pump and water bypass pipe
     
    3 bolts, water pump and gasket, from the water pump cover
     

  8.  

To install:

  1. Install or connect the following:

    Water pump to the water pump cover, using a new gasket. Tighten the 3 bolts to 78 inch lbs. (9 Nm).
     
    New O-ring and gasket to the water pump cover
     
    New O-ring to the water bypass pipe, by applying soapy water to the O-ring
     
    Water pump cover to the water bypass pipe; do not install the nuts at this time
     
    Water pump. Tighten the 3 bolts, in sequence, to 78 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Water pump bolt tightening sequence-2.0L engine

     



    Water pump cover to the water pump pipe. Tighten the 2 bolts to 82 inch lbs. (9 Nm).
     
    Alternator drive belt adjusting bar. Tighten the bolt to 20 ft. lbs. (27 Nm).
     
    CKP connector clamp
     
    No. 2 idler pulley and drive belt tension spring
     
    Lower radiator hose
     
    Drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the engine and radiator with engine coolant.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Install the right side engine undercover.
  8.  

2.4L Engine





Click image to see an enlarged view

Fig. Water pump and related parts-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Remove the water pump pulley.
  8.  
  9. Remove the crankshaft position sensor wire and clamp.
  10.  
  11. Remove the 4 bolts and 2 nuts from the pump.
  12.  
  13. Using a small prybar, remove the water pump.
  14.  
  15. Remove all traces of the gasket material from the pump and block.
  16.  


    Click image to see an enlarged view

    Fig. Pry at these points-2.4L engine


To install:

  1. Apply a 2.5mm wide bead of RTV gasket material to the pump sealing surface as shown.
  2.  


    Click image to see an enlarged view

    Fig. Apply a 2.5mm wide bead of RTV gasket material to the pump sealing surface as shown-2.4L engine



NOTE
Install the pump with 5 minutes of applying the sealer or the sealer will have to be removed and new sealer applied.

  1. Install the pump and torque the nuts and bolts to 80 inch lbs. (9 Nm).
  2.  
  3. The remainder of installation is the reverse of removal. Refill the cooling system.
  4.  



Click image to see an enlarged view

Fig. Water pump and related components-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the water pump pulley.
  10.  
  11. Remove the crankshaft position sensor wire and clamp.
  12.  
  13. Remove the 4 bolts and 2 nuts from the pump.
  14.  
  15. Using a small prybar, remove the water pump.

    Click image to see an enlarged view

    Fig. Water pump removal points-2.4L engine

  16.  
  17. Remove all traces of the gasket material from the pump and block.
  18.  

To install:

  1. Apply a 2.5mm wide bead of RTV gasket material to the pump sealing surface as shown.
    NOTE
    Install the pump with 5 minutes of applying the sealer or the sealer will have to be removed and new sealer applied.

  2.  
  3. Install the pump and torque the nuts and bolts to 80 inch lbs. (9 Nm).
  4.  
  5. The remainder of installation is the reverse of removal. Refill the cooling system.

    Click image to see an enlarged view

    Fig. RTV gasket application-2.4L engine

  6.  

 
label.common.footer.alt.autozoneLogo