Water Pump: Service and Repair

REMOVAL
1. REMOVE AIR CLEANER, MAP METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
2. REMOVE RADIATOR ASSEMBLY
3. REMOVE DRIVE BELT, FAN, FLUID COUPLING ASSEMBLY AND WATER PUMP PULLEY





a) Loosen the 4 nuts holding the fluid coupling to the water pump.





b) Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt.
c) Remove the 4 nuts, the fan, fluid coupling assembly and water pump pulley.
4. REMOVE TIMING BELT AND IDLER PULLEY





5. REMOVE WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE
a) Remove the 2 bolts, water bypass outlet and No.1 water bypass pipe.
b) Remove the 3 O-rings from the water bypass outlet and No.1 water bypass pipe.
6. REMOVE WATER INLET, LOWER RADIATOR HOSE ASSEMBLY AND THERMOSTAT
7. REMOVE WATER PUMP





a) Loosen the nut and remove the bolt, and slightly slide the generator from the water pump.
b) Remove the bolt, and disconnect the clamp bracket.
c) Remove the bolt, and disconnect the connector bracket (for crankshaft position sensor connector).





d) Remove the 2 nuts, and disconnect the No.2 water bypass pipe from the water pump.





e) Remove the 6 bolts, water pump and gasket.
f) Remove the drain hose.
g) Remove the O-ring from the cylinder block.

INSPECTION





1. INSPECT WATER PUMP
Turn the pulley seat, and check that the water pump bearing is not rough or noisy.
If necessary, replace the water pump.
Visually check the air hole and drain hose for coolant leakage.
If leakage is found, replace the water pump.
2. INSPECT FLUID COUPLING





a) Remove the 4 nuts and fan from the fluid coupling.





b) Check that the fluid coupling is not damaged and that no silicon oil leaks.
If necessary, replace the fluid coupling.
c) Reinstall the fan to the fluid coupling with the 4 nuts.
Torque: 7.5 Nm (75 kgf-cm, 65 inch lbs.)

INSTALLATION
1. INSTALL WATER PUMP





a) Install a new O-ring to the cylinder block.
b) Install the drain hose.





c) Install a new gasket to the water pump.
d) Connect the water pump to the water bypass pipe. Do not install the nut yet.





e) Install the water pump with the 2 bolts (A) and 4 bolts (B).
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

HINT: Hand tighten the (A) bolts first.

f) Install the 2 nuts holding the No.2 water bypass pipe to the water pump.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
g) Install the connector bracket (for crankshaft position sensor connector) with the bolt.
h) Install the clamp bracket with the bolt.
i) Install the generator with the bolt and nut.
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)
2. INSTALL THERMOSTAT, WATER INLET AND LOWER RADIATOR HOSE ASSEMBLY
3. INSTALL NO.1 WATER BYPASS PIPE AND WATER BYPASS OUTLET
a) Install 2 new O-rings to the No.1 water bypass pipe.
b) Install a new O-ring and the water bypass outlet with the 2 bolts.
Torque: 9.0 Nm (90 kgf-cm, 80 inch lbs.)





4. INSTALL IDLER PULLEY AND TIMING BELT
5. INSTALL WATER PUMP PULLEY, FAN, FLUID COUPLING ASSEMBLY AND DRIVE BELT
a) Align the matchmarks, and install the water pump pulley, the fan and fluid coupling assembly with the 4 nuts.
b) Install the drive belt by turning the drive belt tensioner clockwise.
c) Stretch the belt tight, and tighten the 4 nuts.
Torque: 16.5 Nm (165 kgf-cm, 12 ft. lbs.)
6. INSTALL RADIATOR ASSEMBLY
7. INSTALL AIR CLEANER, MAF METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
8. ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.