Water Pump: Service and Repair

WATER PUMP COMPONENTS

REMOVAL OF WATER PUMP

1. DRAIN ENGINE COOLANT
2. DISCONNECT RADIATOR INLET HOSE FROM WATER INLET PIPE
3. REMOVE IGNITION COIL (RIGHT SIDE)
(a) Disconnect the connector and high-tension cord.
(b) Remove the three bolts and ignition coil.
(c) Remove the pickup sensor connector.

4. DISCONNECT TIMING BELT





5. REMOVE WATER INLET HOUSING
(a) Disconnect the water hoses from the inlet housing.





(b) Remove the two bolts.
(c) Using a soft faced hammer, carefully tap the inlet housing.





(d) Remove the O-ring.

6. REMOVE WATER PUMP





(a) Remove the five bolts, nut1 and two stud bolts.





(b) Remove the water pump carefully by prying with a screwdriver between the water pump and cylinder block.

HINT: Do not damage the cylinder block and/or water pump.

(c) Remove the O-ring from the water bypass pipe.

INSTALLATION OF WATER PUMP

1. INSTALL WATER PUMP AND INLET HOUSING
(a) Clean any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump, cylinder block and water inlet housing.
- 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) Install a new O-ring to the water bypass pipe.
(c) Apply soapy water to the O-ring.





(d) Apply seal packing to the water pump groove. Seal packing: Part No.08826-00100 or equivalent
- Install a nozzle that has been cut to a 2 - 3 mm (0.08 0.12 in.) opening.

HINT: Avoid applying an excessive amount of seal packing to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube of seal packing and reinstall cap for reuse of the remaining seal packing.

(e) Connect the water pump to the water bypass pipe.





(f) Install the water pump with the five bolts, nut and two stud bolts. Gradually torque each bolt and nut.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)





(g) Install a new O-ring to the water inlet housing.
(h) Apply soapy water to the O-ring.





(i) Apply seal packing to the water inlet housing groove. Seal packing: Part No.08826-00100 or equivalent

- Install a nozzle that has been cut to a 2 - 3 mm (0.08-0.12 in.) opening.

HINT: Avoid applying an excessive amount of seal packing to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube of seal packing and reinstall cap for reuse of the remaining seal packing.





(j) Install the water inlet housing with the two bolts.

Torque: 185 kg-cm (13 ft-lb. 18 N.m)





(k) Connect the water hoses to the inlet housing.

2. INSTALL TIMING BELT
3. INSTALL IGNITION COIL (RIGHT SIDE)
(a) Install the pickup sensor connector.
(b) Install the ignition coil with the three bolts.
(c) Connect the connector and high-tension cord.

4. CONNECT WATER HOSE TO RADIATOR LOWER HOSE
5. REFILL WITH ENGINE COOLANT