Toyota Tacoma 2002-06

Removal & Installation

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1GR-FE Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On 4WD and PreRunner, remove the four retaining bolts and remove the number one engine undercover subassembly.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the radiator support to frame seal, left side.
  10.  
  11. Remove the V bank cover.
  12.  
  13. Remove the fan shroud. Remove the air cleaner assembly.
  14.  
  15. Disconnect the two oil cooler hoses (with oil cooler) and remove the water inlet.
  16.  
  17. Disconnect the radiator hoses. Disconnect the five water bypass hoses.
  18.  
  19. Remove the five bolts and the water inlet. Remove the O-ring from the water outlet pipe. Remove the gasket from the water pump.
  20.  
  21. Remove the two bolts and remove the number two idler pulley subassembly.
  22.  
  23. Remove the alternator.
  24.  
  25. Remove the mounting bolt and separate the air conditioning compressor suction hose subassembly. Disconnect the air condition compressor connector. Remove the four bolts and separate the compressor from the belt tensioner assembly.
  26.  
  27. Remove belt tensioner assembly.
  28.  
  29. Remove the water pump retaining bolts. Remove the water pump from the engine.
  30.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Using a new gasket install the water pump to the engine. Tighten bolts -A- to 80 inch lbs. Tighten bolts -B- to 17 ft. lbs.

    Click image to see an enlarged view

    Fig. Water pump bolt identification-4.0L engine

  4.  
  5. Install the belt tensioner assembly.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks.
  12.  

2RZ-FE & 3RZ-FE Engines



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

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    2 bolts and the air pipe, for the California vehicles with 3RZ-FE engine
     
    Upper radiator hose from the radiator
     
    Oil dipstick guide, by removing the bolt
     
    Power steering drive belt, by loosening the lockbolt and adjusting bolt to the idler pulley, if equipped with power steering
     
    No. 2 fan shroud, by removing the 2 clips
     
    No. 1 fan shroud, by removing the 4 bolts
     
    Loosen the idler pulley nut and adjusting bolt and remove the air conditioning drive belt, if equipped with air conditioning
     

  8.  
  9. Remove the alternator drive belt, fan (with fan clutch), water pump pulley and the fan shroud, as follows:

    Stretch the belt and loosen the water pump pulley mounting nuts
     
    Loosen the lock, pivot and the adjusting bolts for the alternator
     
    Alternator drive belt
     
    4 water pump pulley mounting nuts
     
    Fan (with fan clutch) and the water pump pulley
     

  10.  
  11. Remove the water pump and discard the gasket.
  12.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Apply a thin layer of liquid sealant to a new gasket
     
    Place the gasket and water pump into position. Tighten the 14mm head bolts A to 18 ft. lbs. (25 Nm) and the 12mm head bolts to 78 inch lbs. (9 Nm).
     

  4.  
  5. Install the water pump pulley, fan shroud, fan (with fan clutch) and the alternator drive belt, as follows:

    Fan (with the fan clutch), water pump pulley and the fan shroud in position
     
    Water pump pulley mounting nuts but do not tighten the nuts at this time
     
    Alternator drive belt
     
    Stretch the alternator belt tight. Tighten the fan nuts to 16 ft. lbs. (21 Nm).
     
    Adjust the alternator drive belt
     

  6.  
  7. Install or connect the following:

    Adjust the drive belt, if equipped with air conditioning
     
    No. 1 fan shroud, by installing the 4 bolts
     
    No. 2 fan shroud, with the 2 clips
     
    Adjust the power steering drive belt
     
    Oil dipstick guide, with the bolt
     
    Upper radiator hose to the radiator
     
    Air pipe, If removed
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Install the engine undercover.
  14.  

2TR-FE Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On 4WD and PreRunner, remove the four retaining bolts and remove the number one engine undercover subassembly.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the radiator support to frame seal, left side.
  10.  
  11. Remove the fan shroud. Remove the alternator.
  12.  
  13. Remove the three bolts, and remove the belt tensioner assembly.
  14.  
  15. Remove the water pump retaining bolts. Remove the water pump from the engine.
  16.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Using a new gasket install the water pump to the engine. Tighten bolts -A- to 15 ft. lbs. Tighten bolts -B- to 80 inch lbs.

    Click image to see an enlarged view

    Fig. Water pump bolt identification-2.7L (2TR-FE) engine



    Click image to see an enlarged view

    Fig. Belt tensioner bolt identification and location-2.7L (2TR-FE) engine

  4.  
  5. Install the belt tensioner assembly. Tighten bolt -B- to 30 ft. lbs. Tighten bolt -A- to 16 ft. lbs. Tighten bolt -C- to 32 ft. lbs.
    NOTE
    Check that the bolt holes on the belt tensioner and timing chain cover are aligned, prior to installing bolt -C-.

  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks.
  12.  

5VZ-FE Engines



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

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the upper radiator hose.
  8.  
  9. Remove the power steering drive belt, as follows:

    Stretch the belt and loosen the fan pulley mounting nuts
     
    Loosen the lockbolt, pivot bolt and the adjusting bolt
     
    Drive belt
     

  10.  
  11. Remove or disconnect the following:

    Air conditioning drive belt, by loosening the idler pulley nut and adjusting bolt
     
    Lockbolt, pivot bolt and the adjusting bolt
     
    Alternator drive belt
     
    No. 2 fan shroud, by removing the 2 clips
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump and move it aside without disconnecting the lines from the pump
     
    Compressor from the engine and move it aside without disconnecting the compressor lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     

  12.  
  13. Remove the No. 2 timing belt cover, as follows:

    Camshaft Position (CMP) sensor connector from the No. 2 timing belt cover
     
    3 spark plug wire clamps from the No. 2 timing belt cover
     
    6 bolts and the timing belt cover
     

  14.  
  15. Remove the fan bracket, as follows:

    Power steering adjusting strut, by removing the nut
     
    Fan bracket, by removing the bolt and nut
     

  16.  
  17. Set the No. 1 cylinder to Top Dead Center (TDC) of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark O of the No. 1 timing belt cover.
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).
    4.  

  18.  
  19. Remove the camshaft timing pulleys, as follows:
    1. Remove the timing belt tensioner by alternately loosening the 2 bolts.
    2.  
    3. Using Variable Wrench Set No. 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
    4.  
    5. Remove the 2 timing pulleys with the timing belt.
    6.  

  20.  
  21. Remove or disconnect the following:

    Thermostat
     
    No. 2 oil cooler hose, from the water pump
     
    Water pump, by removing the 7 bolts
     

  22.  
  23. Thoroughly clean the mating surfaces.
  24.  

To install:

Click image to see an enlarged view

Fig. Water pump and related components-3.4L engine

  1. Install or connect the following:
    WARNING
    Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.



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



    Water pump. Tighten the bolts to 14 ft. lbs. (20 Nm).
     
    No. 2 oil cooler hose
     
    Thermostat
     
    Left camshaft timing pulley. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
     

  2.  
  3. Set the No. 1 cylinder to TDC of the compression stroke.
  4.  
  5. Connect the timing belt to the left camshaft timing pulley. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover, as follows:
    1. Using Variable Pin Wrench Set 09960-01000, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left camshaft timing pulley.
    2.  
    3. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    4.  
    5. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    6.  

  6.  
  7. Install the right camshaft timing pulley and the timing belt.
  8.  
  9. Set the timing belt tensioner, as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  
    7. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm).
    8.  
    9. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
    10.  

  10.  
  11. Check the valve timing, as follows:
    1. Slowly turn the crankshaft pulley 2 revolutions from the TDC-to-TDC; always turn the crankshaft pulley clockwise.
    2.  
    3. Check that each pulley aligns with the timing marks. If the timing marks do not align, remove the timing belt and reinstall it.
    4.  

  12.  
  13. Install or connect the following:

    Fan bracket, with the bolt and nut
     
    Remaining components
     
    Negative battery cable
     

  14.  
  15. Fill with engine coolant.
  16.  
  17. Start the engine and check for leaks.
  18.  

 
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