Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA20034 RUNNER 2WD V6-4.0L (1GR-FE)REPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTENGINEWATER PUMPSERVICE AND REPAIR
2003 Toyota 4 Runner 2WD V6-4.0L (1GR-FE)
Water Pump: Service and Repair
2003 Toyota 4 Runner 2WD V6-4.0L (1GR-FE)SECTION Service and Repair
REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1
a. Remove the 4 bolts and engine under cover.
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER
4. REMOVE RADIATOR SUPPORT SEAL UPPER
a. Remove the 11 clips and radiator support seal upper.
5. LOOSEN FAN W/ FLUID COUPLING
a. Loosen the 4 fluid coupling bolts.
6. REMOVE FAN AND GENERATOR V BELT
7. REMOVE FAN W/ FLUID COUPLING
a. Unfasten the hose clamp, and then separate the 2 oil cooler hoses from the fan shroud.
b. Disconnect the radiator reserve tank hose.
c. Remove the 2 fan shroud bolts and radiator reserve tank bolt.
d. Remove the 4 fluid coupling nuts, and then remove the fan w/ fluid coupling and fan shroud together.
e. Remove the fan pulley.
8. DISCONNECT VENTILATION HOSE NO.2
9. REMOVE AIR CLEANER ASSY
10. REMOVE WATER INLET
a. Disconnect the 2 oil cooler hoses (w/ oil cooler).
b. Disconnect the 2 radiator hoses.
c. Disconnect the 5 water by-pass hoses.
d. Remove the 5 bolts and water inlet.
e. Remove the O-ring from the water outlet pipe.
f. Remove the gasket from the water pump.
11. REMOVE IDLER PULLEY SUB-ASSY NO.2
a. Remove the 2 bolts and 2 idler pulleys.
12. REMOVE GENERATOR ASSY
13. SEPARATE COOLER COMPRESSOR ASSY
14. REMOVE V-RIBBED BELT TENSIONER ASSY
15. REMOVE WATER PUMP ASSY
a. Remove the 17 bolts, water pump and gasket.
16. INSTALL WATER PUMP ASSY
a. Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
23 Nm (235 kgf-cm, 17 ft. lbs.) for 12 mm (0.47 inch) head
17. INSTALL V-RIBBED BELT TENSIONER ASSY
18. INSTALL COOLER COMPRESSOR ASSY
19. INSTALL GENERATOR ASSY
20. INSTALL IDLER PULLEY SUB-ASSY NO.2
a. Install the 2 idler pulleys with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
21. INSTALL WATER INLET
a. Install a new O-ring to the water outlet pipe.
b. Install a new gasket to the water pump.
c. Apply soapy water to the O-ring.
d. Install the water inlet with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Connect the 5 water by-pass hoses.
f. Connect the 2 radiator hoses.
g. Connect the 2 oil cooler hoses (w/ oil cooler).
22. INSTALL AIR CLEANER ASSY
23. CONNECT VENTILATION HOSE NO.2
24. INSTALL FAN W/ FLUID COUPLING
a. Put the fan pulley to the water pump.
b. Put the fan w/ fluid coupling and fan shroud together.
c. Temporarily install the 4 fluid coupling nuts.
d. Tighten the 2 fan shroud bolts and radiator reserve tank bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
e. Connect the reserve tank hose.
f. Fasten the 2 oil cooler hoses with the hose clamp.
25. INSTALL FAN AND GENERATOR V BELT
26. FULLY TIGHTEN FAN W/ FLUID COUPLING
a. Tighten the 4 fluid coupling bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
27. INSTALL RADIATOR SUPPORT SEAL UPPER
28. ADD ENGINE COOLANT
29. CHECK FOR ENGINE COOLANT LEAKS
30. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
31. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
a. Install the engine under cover with the 4 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
1. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1
a. Remove the 4 bolts and engine under cover.
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER
4. REMOVE RADIATOR SUPPORT SEAL UPPER
a. Remove the 11 clips and radiator support seal upper.
5. LOOSEN FAN W/ FLUID COUPLING
a. Loosen the 4 fluid coupling bolts.
6. REMOVE FAN AND GENERATOR V BELT
7. REMOVE FAN W/ FLUID COUPLING
a. Unfasten the hose clamp, and then separate the 2 oil cooler hoses from the fan shroud.
b. Disconnect the radiator reserve tank hose.
c. Remove the 2 fan shroud bolts and radiator reserve tank bolt.
d. Remove the 4 fluid coupling nuts, and then remove the fan w/ fluid coupling and fan shroud together.
e. Remove the fan pulley.
8. DISCONNECT VENTILATION HOSE NO.2
9. REMOVE AIR CLEANER ASSY
10. REMOVE WATER INLET
a. Disconnect the 2 oil cooler hoses (w/ oil cooler).
b. Disconnect the 2 radiator hoses.
c. Disconnect the 5 water by-pass hoses.
d. Remove the 5 bolts and water inlet.
e. Remove the O-ring from the water outlet pipe.
f. Remove the gasket from the water pump.
11. REMOVE IDLER PULLEY SUB-ASSY NO.2
a. Remove the 2 bolts and 2 idler pulleys.
12. REMOVE GENERATOR ASSY
13. SEPARATE COOLER COMPRESSOR ASSY
14. REMOVE V-RIBBED BELT TENSIONER ASSY
15. REMOVE WATER PUMP ASSY
a. Remove the 17 bolts, water pump and gasket.
16. INSTALL WATER PUMP ASSY
a. Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
23 Nm (235 kgf-cm, 17 ft. lbs.) for 12 mm (0.47 inch) head
17. INSTALL V-RIBBED BELT TENSIONER ASSY
18. INSTALL COOLER COMPRESSOR ASSY
19. INSTALL GENERATOR ASSY
20. INSTALL IDLER PULLEY SUB-ASSY NO.2
a. Install the 2 idler pulleys with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
21. INSTALL WATER INLET
a. Install a new O-ring to the water outlet pipe.
b. Install a new gasket to the water pump.
c. Apply soapy water to the O-ring.
d. Install the water inlet with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Connect the 5 water by-pass hoses.
f. Connect the 2 radiator hoses.
g. Connect the 2 oil cooler hoses (w/ oil cooler).
22. INSTALL AIR CLEANER ASSY
23. CONNECT VENTILATION HOSE NO.2
24. INSTALL FAN W/ FLUID COUPLING
a. Put the fan pulley to the water pump.
b. Put the fan w/ fluid coupling and fan shroud together.
c. Temporarily install the 4 fluid coupling nuts.
d. Tighten the 2 fan shroud bolts and radiator reserve tank bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
e. Connect the reserve tank hose.
f. Fasten the 2 oil cooler hoses with the hose clamp.
25. INSTALL FAN AND GENERATOR V BELT
26. FULLY TIGHTEN FAN W/ FLUID COUPLING
a. Tighten the 4 fluid coupling bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
27. INSTALL RADIATOR SUPPORT SEAL UPPER
28. ADD ENGINE COOLANT
29. CHECK FOR ENGINE COOLANT LEAKS
30. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
31. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
a. Install the engine under cover with the 4 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.