Water Pump

Replace the engine water pump on a 2008 Toyota Highlander 3.5L V6 AWD, including coolant drain, accessory drive belt removal, and timing cover access.

Warnings

Tools required

Parts

• Water pump assembly with gasket × 1 — OEM 16100-39455 or equivalent
• Engine coolant × 1 — Toyota Super Long Life Coolant (red)
• Accessory drive belt × 1 — Inspect and replace if worn

Fluids

• Toyota Super Long Life Coolant (red) — 9.2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 2 hours after operation)
3. Disconnect negative battery cable
4. Raise and support front of vehicle on jack stands
5. Remove engine splash shield/under cover fasteners and lower shield
6. Place large drain pan beneath radiator drain cock

Procedure

1. 1

   Drain Engine Coolant
   Open radiator drain cock at bottom of radiator driver's side. Remove radiator cap to allow complete drainage. Drain coolant into appropriate container. Once drained, close drain cock securely.
2. 2

   Remove Accessory Drive Belt
   Locate serpentine belt tensioner on front of engine (below alternator). Insert 3/8" ratchet or tensioner tool into tensioner square hole. Rotate tensioner clockwise to release belt tension. Slide belt off pulleys and slowly release tensioner. Remove belt from engine bay. Inspect belt for cracks, glazing, or rib damage.
3. 3

   Remove Right Engine Mount
   Engine mount removal is generally not required for water pump access on the 2GR-FE. If clearance is needed, support the engine and relocate accessory components as necessary, but the water pump is accessible after drive belt removal without disturbing timing components.
4. 4

   Remove Timing Belt Covers
   No timing belt cover removal is required. The 2GR-FE water pump is externally mounted on the front of the engine and is accessible after the accessory drive belt is removed. Skip to water pump bolt removal.
5. 5

   Disconnect Coolant Hoses from Water Pump
   Locate lower radiator hose connection to water pump inlet on driver's side. Use pliers to squeeze and slide hose clamp back on hose. Twist and pull hose off water pump inlet. Locate heater hose connection to water pump. Release clamp and remove heater hose. Have rags ready as residual coolant will drain.
6. 6

   Remove Water Pump Bolts
   Remove the water pump mounting bolts (verify exact count and size against the FSM — typically 10mm head bolts of varying lengths). Note bolt locations as some bolts are different lengths. Remove bolts gradually in a diagonal pattern.
7. 7

   Remove Water Pump Assembly
   Carefully pry the water pump away from the engine block using a plastic pry tool. The water pump is sealed with a gasket and may require gentle persuasion. Once loose, pull the pump straight off. Remove and discard old gasket material from the engine block mounting surface.
8. 8

   Clean Mounting Surfaces
   Use plastic gasket scraper to remove all old gasket material from engine block water pump mounting surface. Clean surface with clean rag and brake cleaner. Inspect surface for gouges or damage. Surface must be completely clean and dry for proper seal.
9. 9

   Install New Water Pump
   Position the new gasket/O-ring on the water pump or engine block per gasket design. Carefully align the water pump with the mounting holes, ensuring the gasket stays in position. Start all mounting bolts by hand to ensure proper alignment.
   Torque spec

   Water Pump Bolts25 Nm (18 lb-ft)
10. 10

    Torque Water Pump Bolts
    Tighten water pump bolts in a criss-cross pattern. Torque to FSM specification (typically around 10 Nm / 7 lb-ft for M6 bolts; verify exact value per service manual). Make a second pass to verify all bolts are properly torqued.
    Torque spec

    Water Pump Bolts25 Nm (18 lb-ft)
11. 11

    Reconnect Coolant Hoses
    Install lower radiator hose onto water pump inlet. Ensure hose is fully seated on pump neck. Position hose clamp over connection point and tighten securely. Install heater hose to water pump and secure with clamp. Verify both connections are tight and hoses are properly routed without kinks.
12. 12

    Reinstall Timing Belt Covers
    No timing belt covers exist on this engine; skip this step. Proceed to reinstall any accessory components removed for access.
13. 13

    Reinstall Right Engine Mount
    Position engine mount bracket on engine block and install 3 mounting bolts. Tighten bolts securely. Align engine mount through-bolt hole and install 17mm through-bolt. Torque through-bolt to specification. Remove engine support fixture or floor jack.
14. 14

    Install Accessory Drive Belt
    Route new or inspected belt around all pulleys according to belt routing diagram (typically on radiator support or under hood). Ensure belt is properly seated in all pulley grooves. Rotate tensioner clockwise with ratchet and slip belt over final pulley. Slowly release tensioner to apply proper tension. Verify belt alignment on all pulleys.
15. 15

    Refill Coolant System
    Pour Toyota Super Long Life Coolant (red) into radiator until full. Fill coolant reservoir to MAX line. Leave radiator cap off. Start engine and allow to warm to operating temperature with heater on full hot. Watch coolant level and add as needed while engine burps air from system. Once engine reaches operating temperature and upper radiator hose is hot, top off coolant and install radiator cap. Check for leaks around water pump and hose connections.

Reassembly

1. Reinstall engine splash shield with all fasteners
2. Lower vehicle from jack stands
3. Reconnect negative battery cable
4. Allow engine to reach full operating temperature and recheck coolant level after cool-down
5. Inspect for coolant leaks at water pump, hoses, and timing cover area during first test drive

Verification

• Start engine and verify no coolant leaks from water pump or hose connections
• Confirm accessory belt runs smoothly without slipping or squealing
• Verify engine reaches normal operating temperature without overheating
• Check coolant level after engine reaches full operating temperature and cools
• Inspect under vehicle for any coolant drips after 24 hours of operation