2.0D4D Water Pump Replacement

[Tofuman1990]

Hey everyone new to the forum, i just picked up a 54 plate Avensis 2.0D4D with 100,000 miles on it car is immaculate inside and out. Service histoy however was stopped at 60,000 miles for some reason but has a new starter stamped 2013 on it so somebodies been looking after it.

Because of the lack of history the first thing i did was opted to change oil and filters and the timing belt, i always do a water pump when i change a timing belt so naturally bought that too.

However upon removing everything , timing the engine and removing the old belt , i began removing the pulleys then i noticed to remove the water pump you have to remove the fuel pump sprocket ?!?!! What on earth is this design.

Noticed two threaded holes in the sprocket possibly to lock it in place to remove the large nut on the sprocket.... but nothing to thread them into on the back plate.

Tried wedging it with metal objects couldn't undo the large nut.

Tried impact gun but couldn't fit it in the space between the chassis and the fuel pump.

Am i missing something here ? has anyone done a water pump on these and remember how to do it?

8 hours later i was loosing patience and needed the car so i just changed the pulleys, tensioner and new belt inspected the water pump for leaks and found none so had to just leave it.

[Bono Estente]

Did you manage to take any pictures at all. I need to do this job too...so gathering as much info as I can...

cant find anything on water pump though...I ordered a new one and was surprised how big it was....its like half the side of the engine?.....does it really have to be this big?.....I mean really?.

In the rav4 forum there is a how to on the timing belt change and a few pdfs that show how to remove the pullys and bolts..

[Tofuman1990]

I didnt take many pictures to be honest , the timing belt itself was a straight forward enough job just time consuming , took the best part of 6-8 hours for the full job on my own including an oil and filter change.

Hell knows why they designed the water pump this way, im sure the 2.2 D4D is just a standalone pump which can be removed easily where as the 2.0 has it going behind the high pressure fuel pump pulley which was impossible to remove for me without breaking something.... so in the end i just changed the timing belt , and both pulleys and tensioner... not advisable i know but water pump was not leaking or making any rough sounds when spun so i guess it will just need to hold up for a while longer

[Konrad C]

Have you tried Youtube?

I have posted the following links:

Look for Liamautomechanic. There may be others who show the water pump being changed.

[Bono Estente]

Yep tired youtube, Google etc...But nothing on the water pump on a 2.0 D4D engine???

[Bono Estente]

I didnt take many pictures to be honest , the timing belt itself was a straight forward enough job just time consuming , took the best part of 6-8 hours for the full job on my own including an oil and filter change.

Hell knows why they designed the water pump this way, im sure the 2.2 D4D is just a standalone pump which can be removed easily where as the 2.0 has it going behind the high pressure fuel pump pulley which was impossible to remove for me without breaking something.... so in the end i just changed the timing belt , and both pulleys and tensioner... not advisable i know but water pump was not leaking or making any rough sounds when spun so i guess it will just need to hold up for a while longer

Ive just had a look at mine, and your right, its going to be very time consuming, lots have to come out, just to gain access, and the water pump is well burried under pullys, and the side of the chassis rail..

[Tofuman1990]

Spoke to a mechanic who has done a few of these said they are a pain in the back passage , you have to find a way to lock the fuel pump pulley in place then use a impact gun or air ratchet to remove the fuel pump pulley bolt , after that you need to use a bearing puller which screws into the pulley and then you use the impact gun on the puller to wind in and pull the pulley off the shaft. this allows you to remove the water pump.... says a lot of places opt to not change the water pump if its not leaking because of this.


I had access to all of these tools and still could not remove the fuel pump pulley as i couldn't get it to lock in place to undo the bolt

[Bono Estente]

I wonder if the pulley bolt would come off if you locked the crankshaft by putting it in gear and foot on brake pedal...before you actually took the belt off?

might try it....

[Tofuman1990]

By going with how tight the bolt was when i tried it you will likely just stretch and ruin the belt.... it was tight

As in two bolts locking the pulley and a pry bar and bent both bolts tight

[avensisd4d786]

does this help guys?

RM1039Supp620.pdf

[avensisd4d786]

does anyone know if the waterpump on the rav 4 1cd-ftv is different to the one that fits the 2004 avensis.

part number for mine is 16100-29185. rav4 part number is 16100-29135.

this is what I have read (there are two types of water pumps that fit this engine so make sure that is the one right for you - it is the mounting bolts layout that is different)

[avensisd4d786]

I think I have answered my own question. highlighted are the mounting bolts. do you agree?

first attachment is from the 16100-29135

second attachment is from the 16100-29135

[Bono Estente]

Those two lugs are where the injection pump bolts onto...its this that is awkward to get at and requires half the injection pipes to be removed just to gain access to the bolts...apparently..?

hmm I wonder if they changed the bolts location for easier access on later models?......I hope so as a have a later 05 Rav.

And well spotted it does appear that they are different.....sneaky buggers Toyota

heres some pics of my FAI one...

[avensisd4d786]

according to my research 16100-29135 is fitted to the

• 2.0-litre D-4D 1CD-FTV 81 kW (109 hp) (corolla e11, corolla verso 01-03 avensis t22, avensis verso 01-03,picnic,previa, rav4 01-05)

and the 16100-29185 fits the;

• 2.0-litre D-4D 1CD-FTV 85 kW (114 hp) (avensis t25 (mine), corolla, avensis verso 04+)

[Bono Estente]

Interesting the same engine but with different power outputs? I used to think they were all exactly the same throughout the range.

I better double check my water pump is compatible.

I wonder if the injection pump is different too? As the different mounting points and the increase in engine power output....

[Parts-King]

You very often find the same block and engine type run for several years, but over those years, power can be increased in a number of ways, better fuel delivery / injectors / pump / ECU etc. You then find that ancillaries have to change to accommodate those new parts. It has nothing to do with making something easier to fit ;)

[avensisd4d786]

Interesting the same engine but with different power outputs? I used to think they were all exactly the same throughout the range.

I better double check my water pump is compatible.

I wonder if the injection pump is different too? As the different mounting points and the increase in engine power output....

yours is correct, there is only one fitted to the 01-05 range of the rav4 and its the one you have. same as the one on top of the yellow box in one of my pictures.

[Bono Estente]

Great stuff....so do these uprated engines have different version numbers eg rev1 rev2 etc

[avensisd4d786]

the only other difference I can see the 109 is EURO 3 and the 114 is Euro 4.

[Bono Estente]

Now I see, it must be for the newer emision regulations.....

[Bono Estente]

Well Ive just had a closer look at the underneath of my engine after spending 5 days driving around the welsh countryside....and it looks like the pump may be leaking as I have pink coolant around that area....So whether i like it or not its pump change for me...Im glad in a way because now i will have to change it, however long it takes........Might start it saturday, I will try and take some pictures if I dont get anoyed with it....

[elpaso]

Hi All

My video on You tube:

http://youtu.be/knCSAxDSH7s

-Timing belt and water pump change.

Mod Edit

Just a small tweak to allow direct access to the video

[Bono Estente]

Thanks again...Muchas Gracias!!

[avensisd4d786]

Thank you very much elpaso. This will help me next month and hopefully other members in the future

Ex vec you seen this?

:

[avensisd4d786]

Video does not work for me anymore.