Water Pump: Service and Repair

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE TIMING BELT
3. REMOVE NO.2 IDLER PULLEY





4. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY
a. Disconnect the water bypass hose from the water inlet housing.
b. Remove the 2 bolts holding the water inlet housing to the water pump.
c. Disconnect the water inlet housing from the front water bypass joint, and remove the water inlet and inlet housing assembly.
d. Remove the O-ring from the water inlet housing.
5. REMOVE WATER PUMP





a. Remove the 5 bolts, 2 stud bolts and nut.





b. Using a screwdriver, remove the water pump by prying the portions between the water pump and cylinder block.
c. Remove the O-ring from the water bypass pipe.

INSPECTION





1. INSPECT WATER PUMP
a. Visually check the air hole and water hole for coolant leakage.
If leakage is found, replace the water pump and timing belt.
b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT TIMING BELT COMPONENTS

INSTALLATION
1. INSTALL WATER PUMP
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove ail the loose material.
- Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the water pump as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





c. Install a new O-ring to the water bypass pipe end.
d. Apply soapy water to the O-ring.
e. Connect the water pump to the water bypass pipe end.
f. Install the water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.)

HINT: Use bolts 30 mm (1.18 inch) in length.

2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water in-let housing and water pump.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the sealing groove of water inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





c. Install a new O-ring to the water inlet housing.
d. Apply soapy water on the O-ring.
e. Attach the water inlet housing end to the front water bypass joint hole.
f. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.)

HINT: Each bolt length is indicated in the illustration.

Bolt length:
76 mm (3.00 inch) for A
22 mm (0.87 inch) for B

g. Connect the water bypass hose to the water inlet housing.
3. INSTALL NO.2 IDLER PULLEY
4. INSTALL TIMING BELT
5. FILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS