Radiator Cooling Fan Pump: Service and Repair
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER
Remove the 2 bolt, 2 nuts and V-bank cover.
4. REMOVE INTAKE AIR CONNECTOR
Remove the bolt and engine wire cover.
5. DISCONNECT UPPER RADIATOR HOSE
6. REMOVE A/C COMPRESSOR
7. REMOVE TIMING BELT COVERS
8. DISCONNECT PRESSURE AND SUCTION HOSES FROM HYDRAULIC PUMP
9. REMOVE HYDRAULIC PUMP
a) Disconnect the solenoid valve connector.
b) Remove the 2 bolts and 2 nuts.
c) Disconnect the crankshaft position sensor wire clamp.
d) Remove the hydraulic pump.
DISASSEMBLY
1. REMOVE SUCTION PORT UNION
a) Remove the bolt.
b) Pull out the port union.
c) Remove the O-ring from the port union.
2. REMOVE WIRE CLAMP
a) Remove the wire clamp from the rear housing.
b) Remove the wire clamp from the lead wire and connector.
3. MOUNT REAR HOUSING
Mount the parts in a vise as shown in the illustration.
4. REMOVE SOLENOID VALVE
a) Remove the solenoid valve.
b) Remove the O-ring from the solenoid valve.
c) Remove the O-ring from the rear housing.
5. REMOVE PUMP PULLEY
a) Using SST, remove the pulley nut by turning it clockwise.
SST 09960-10010
b) Using SST, remove the pulley.
SST 09286-06011
6. REMOVE FRONT HOUSING
a) Remove the 5 bolts.
b) Using a plastic-faced hammer, carefully tap out the front housing.
c) Remove the O-ring from the casing.
7. REMOVE FRONT THRUST WASHER
8. REMOVE DRIVE SHAFT
9. REMOVE DRIVE AND DRIVEN ROTORS
10. REMOVE REAR THRUST WASHER
11. REMOVE CASING
a) Remove the casing.
b) Remove the O-ring from the rear housing.
12. REMOUNT REAR HOUSING
Mount the parts in a vise as shown in the illustration.
13. REMOVE SPOOL VALVE
a) Using a 10 mm hexagon wrench, remove the end plug.
b) Remove the spool valve.
c) Remove the compression spring.
d) Remove the spool sleeve.
e) Remove the O-ring from the end plug.
INSPECTION
1. CLEAN DISASSEMBLED PARTS
Using a cleaner and compressed air, clean the disassembled parts.
CAUTION: Thoroughly clean the oil passages of the rear housing. Oil passage A includes a filter which should be cleaned carefully.
2. INSPECT SPOOL VALVE
a) Coat the spool valve with fluid, and check that it falls smoothly into the spool sleeve by its own weight.
b) Check the spool valve for leakage.
Close one of the holes and apply compressed air 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) into the opposite side, check that air does not come out of the end hole.
If it doesn't, replace the spool valve and sleeve as a set.
3. INSPECT SPOOL COMPRESSION SPRING
Using vernier calipers, measure the free length.
Free length: 45.8 mm (1.803 inch)
If the free length is not as specified, replace the spring.
4. INSTALL CASING AND ROTORS TO REAR HOUSING
Face the dot mark of the rotors upward.
5. INSPECT ROTOR SIDE CLEARANCE
HINT: Before measuring the clearance, remove one side of the rotors. Using a feeler gauge and precision straight edge, measure the side clearance between the rotor and precision straight edge.
Side clearance:
Maximum side clearance:
If the clearance is greater the maximum, replace the rotors as a set. If necessary, replace the housings.
6. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driven rotor and casing.
Body clearance:
If the clearance is greater the maximum, replace the rotors as a set. If necessary, replace the casing.
7. INSPECT ROTOR TIP CLEARANCE
Using a feeler gauge, measure the clearance of all the 6 drive rotor tips between the drive and driven rotors.
Tip clearance:
If the clearance is greater the maximum, replace the rotors as a set.
8. REMOVE ROTORS AND CASING FROM REAR HOUSING
9. INSPECT OIL CLEARANCE OF DRIVE SHAFT
a) Using a caliper gauge, measure the bushing inside diameter on the housings.
Bushing hole inside diameter: 17.000 - 17.050 mm (0.6693 - 0.6713 inch)
b) Using a micrometer, measure the drive shaft diameter.
Shaft diameter: 16.970 - 16.980 mm (0.6681 - 0.6685 inch)
c) Subtract the drive shaft diameter measurement from the bushing inside diameter measurement.
Oil clearance:
If the clearance is greater the maximum, replace the shaft. If necessary, replace the housings.
10. INSPECT SOLENOID VALVE
Using an ohmmeter, measure the resistance between the terminals.
Resistance: 7.5 - 8.5 Ohms at 20°C (68 °F)
If the resistance is not as specified, replace the sensor.
REPLACEMENT
1. REMOVE OIL SEAL
Using SST and a hammer, tap out the oil seal.
SST 09631-10030
NOTICE: Be careful not to damage the housing.
2. INSTALL OIL SEAL
a) Using a 22 mm socket wrench and hammer, tap in a new oil seal until its surface is flush with the housing edge.
b) Apply fluid to the oil seal lip.
REASSEMBLY
HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new fluid to all sliding and rotating surfaces.
1. MOUNT REAR HOUSING
Mount the parts in a vise as shown in the illustration.
2. INSTALL SPOOL VALVE
a) Align the small hole of the spool sleeve with the hole of the rear housing, and insert the spool sleeve into the rear housing.
b) Insert the compression spring and spool valve into the spool sleeve on the rear housing.
c) Install the a new O-ring to the end plug.
d) Apply fluid to the new O-ring.
e) Temporarily install the end plug.
f) Insert a 5 mm (0.19 inch) straight pin through the holes of the rear housing and spool sleeve.
g) Using a 10 mm hexagon wrench, install the end plug.
Torque: 19 Nm (200 kgf-cm, 14 ft. lbs.)
h) Pull out the straight pin.
3. REMOUNT REAR HOUSING
Mount the parts in a vise as shown in the illustration.
4. INSTALL CASING
HINT: If rubber from the new O-rings adheres to the O-ring INSTALLATION, replace the casing.
a) Install a new O-ring to the rear housing groove.
b) Align the pin hole of the casing with the straight pin on the rear housing, and install the casing.
5. INSTALL REAR THRUST WASHER
6. INSTALL DRIVEN AND DRIVE ROTORS
Install the drive and driven rotors with the dot mark facing upward.
7. INSTALL DRIVE SHAFT
8. INSTALL FRONT THRUST WASHER
9. INSTALL FRONT HOUSING
a) Install a new O-ring to the casing groove.
b) Align the pin holes of the front housing with the straight pin, and place the front housing on the casing.
c) Apply a light coat of fluid on the threads and under the heads of the bolts.
d) Install the front housing with the 5 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
10. CHECK DRIVE SHAFT PRELOAD
a) Check that the drive shaft rotates smoothly without abnormal noise.
b) Temporarily install the pulley nut, and check the rotating torque.
Rotating torque: 0.3 Nm (3.0 kgf-cm, 2.7 inch lbs.)
11. INSTALL PUMP PULLEY
a) Slide the pulley onto the drive shaft.
b) Measure the clearance between the pulley end and drive shaft end.
Clearance:
If the clearance is less than the minimum, replace the pulley.
c) Using SST, install the pulley with the nut. Tighten the nut by turning it counterclockwise.
SST 09960-10010
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
12. INSTALL SOLENOID VALVE
a) Install a new O-ring to the solenoid valve.
b) Install a new O-ring to the rear housing groove.
c) Apply fluid to the two O-rings.
d) Install the solenoid valve.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
13. INSTALL WIRE CLAMP
a) Install the wire clamp to the lead wire and connector.
b) Install the wire clamp to the rear housing.
14. INSTALL SUCTION PORT UNION
a) Install a new O-ring to the port union.
b) Apply fluid to the new O-ring.
c) Install the port union with the bolt.
Torque: 13 Nm (135 kgf-cm, 10 ft. lbs.)
INSTALLATION
1. INSTALL HYDRAULIC PUMP
2. CONNECT PRESSURE AND SUCTION HOSES TO HYDRAULIC PUMP
a) Connect the pressure hose with a new gasket and the union bolt.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
b) Connect the suction hose.
3. INSTALL TIMING BELT COVERS
4. INSTALL A/C COMPRESSOR
5. CONNECT UPPER RADIATOR HOSE
6. INSTALL INTAKE AIR CONNECTOR
Install the bolt.
7. INSTALL V-BANK COVER
Install the V-bank cover with 2 nuts and 2 bolt.
8. FILL WITH ENGINE COOLANT
9. FILL WITH COOLING FAN FLUID
10. START ENGINE AND CHECK FOR LEAKS
11. RECHECK ENGINE COOLANT LEVEL
12. RECHECK COOLING FAN FLUID LEVEL
13. INSTALL ENGINE UNDER COVERS