Water Pump: Service and Repair

WATER PUMP COMPONENTS

REMOVAL OF WATER PUMP
1. DRAIN COOLANT
(a) Remove the radiator cap.

(b) Drain the coolant from the radiator cock and engine drain plug or cock.

2. (4A-GE) REMOVE PS AND/OR A/C DRIVE BELT
3. LOOSEN WATER PUMP PULLEY AND REMOVE ALTERNATOR DRIVE BELT

(a) Loosen the water pump pulley bolts.

(b) Loosen the lock bolt and pivot nut.
(c) Move the alternator fully right, and remove the drive belt.

4. (4A-F, 4A-FE) REMOVE PS DRIVE BELT
5. REMOVE WATER PUMP PULLEY
Remove the four bolts and pump pulley.

6. REMOVE WATER INLET PIPE

(a) Disconnect the water inlet and water by-pass hoses from the inlet pipe.

(b) Remove the two nut and clamp bolts.
(c) Remove the water inlet pipe and 0-ring.

7. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK
Remove the mounting bolt and pull out the dipstick guide and gauge.

NOTE: After pulling out the oil dipstick guide, be sure to plug the oil pump body hole.

8. REMOVE NO.3 AND NO.2 TIMING BELT COVERS

9. REMOVE WATER PUMP
Remove the three bolts and water pump.

CAUTION: Be careful not to get coolant on the timing belt.

INSPECTION OF WATER PUMP

INSPECT WATER PUMP
Turn the pulley and check that the water pump bearing moves smoothly and quietly.

INSTALLATION OF WATER PUMP
1. INSTALL WATER PUMP

Place a new 0-ring on the block and install the pump with three bolts. Torque the bolts.
Torque: 150 kg-cm (11 ft-lb, 15 N-m)

2. INSTALL NO.2 AND NO.3 TIMING BELT COVERS
3. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK

(a) Install a new 0-ring on the oil dipstick guide.
(b) Apply small amount of engine oil to 0-ring.
(c) Push in the oil dipstick guide with the 0-ring.
(d) Install the mounting bolt.

4. INSTALL INLET PIPE

(a) Install the inlet pipe and a new 0-ring to the water pump with the two nuts.

Torque:
4A-F, 4A-FE: 200 kg-cm (14 ft-lb, 20 N-m)
4A-GE: 95 kg-cm (82 in.-lb, 9.3 N-m)

(b) Install the inlet pipe clamp bolt.

Install the water pump pulley and partially tighten the four bolts.
6. (4A-F 4A-FE) INSTALL PS DRIVE BELT
7. INSTALL ALTERNATOR DRIVE BELT
(a) Place the drive belt on the each pulley and set up the drive belt.
(b) Tighten the four bolts of the water pump pulley.

8. (4A-GE) INSTALL PS AND/OR A/C DRIVE BELT
9. ADJUST DRIVE BELT TENSION

Belt tension gauge
Nippondenso BTG-20 (95506-000200)
Borroughs No. BT-33-73F

Drive belt tension:

4A-F, 4A-FE
Alternator
New belt: 160 ± 20 lb
Used belt: 130 ± 20 lb

PS
New belt: 125 ± 25 lb
Used belt: 80 ± 20 lb

A/C
New belt: 160 ± 20 lb
Used belt: 100 ± 20 lb

4A-GE
Alternator
New belt: 175 ± 5 lb
Used belt:P 115 ± 20 lb

PS and/or A/C
New belt: 175 ± 5 lb
Used belt: 115 ± 20 lb

10. REFILL WITH COOLANT
11. START ENGINE AND CHECK FOR LEAKS