Repair Procedures

Removal

Water Pump
1. Loosen the drain plug, and drain the engine coolant.

CAUTION:
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

2. Turn the tensioner counterclockwise and loosen then remove the drive belt (A).




3. Remove the water pump pulley (A).




4. Remove the water pump (A) and the gaskets (B).









Water Temperature Control Assembly
1. Disconnect the battery negative cable.
2. Loosen the drain plug and drain the engine coolant.
3. Remove the intake air hose and air cleaner assembly.
4. Remove the radiator upper hose (A).








5. Disconnect the heater hoses (A).




6. Remove the surge tank.
7. Remove the oil level gauge (A) and the water inlet pipe & hose (B).




8. Remove the water outlet pipe (A).




9. Remove the water temperature control assembly (A) and the gaskets.






Inspection

1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

NOTE:
A small amount of "weeping" from the bleed hole is normal.

Installation

Water Pump
1. Install the water pump.
Install the new gaskets (B) and then install the water pump (A).









NOTE:
- Clean the contact face before assemble.
- Always use a new seal bolt (Bolt C) and the gaskets.

Tightening torque
A (3EA) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
B (1EA) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
C (1EA) :
19.6 - 26.5N.m (2.0 - 2.7kgf.m, 14.5 - 19.5lb-ft)
D (1EA) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
E (1EA) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
F (1EA) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
G (4EA) :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)




2. Install the water pump pulley (A).

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




3. Rotate the auto tensioner counterclockwise. With the tensioner turned, install the drive belt (A).




4. Fill the radiator with coolant and check for leaks.

Water Temperature Control Assembly
1. Install the water temperature control assembly (A) with a new gasket.

Tightening torque :
19.6 - 23.5Nm (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)




2. Install the water outlet pipe (A).

Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)




3. Install the water inlet pipe & hose (B) and the oil level gauge (A).

Tightening torque
Oil level gauge bolt :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
Water inlet pipe bolt :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)




4. Install the surge tank.
5. Connect the heater hoses (A).




6. Install the radiator upper hose (A) and lower hose (B).








7. Install the intake air hose and air cleaner assembly.
8. Connect the battery negative cable.

NOTE:
- Refill engine coolant.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
- Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.