Removal and Installation

WATER PUMP


Removal and Installation


CAUTION:
- When removing water pump assembly, be careful not to get engine coolant on timing chain and drive belt.
- Water pump cannot be disassembled and should be replaced as a unit.
- After installing water pump, connect hoses and clamps securely, then check for leaks.

REMOVAL
1. Remove engine under cover. Service and Repair.
2. Drain engine coolant from radiator. Service and Repair.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on timing chain and drive belt.
3. Remove air duct and resonator assembly. Exploded View.
4. Remove drive belt. Removal And Installation.
5. Remove radiator hose (upper).

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
6. Remove coolant reservoir hose from the radiator.

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
7. Remove engine cooling fan (Motor driven type). Removal and Installation (Motor Driven Type).
8. Set No. 1 cylinder at TDC.





- Rotate crankshaft pulley clockwise to align timing mark (A)
(grooved line without color) with timing indicator (B).
9. Remove engine cooling fan (Crankshaft driven type). Removal and Installation (Crankshaft Driven Type).





10. Remove water drain plug (front) (1).





11. Remove chain tensioner cover and water pump cover from front timing chain case, using Tool.






12. Remove timing chain tensioner (primary) as follows:





a. Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).
b. Depress plunger into tensioner body by pressing slack guide (2).
c. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold plunger in.





d. Remove timing chain tensioner bolts and remove timing chain tensioner (primary).

CAUTION:
Be careful not to drop timing chain tensioner bolts inside timing chain case.
13. Remove water pump as follows:





a. Make a gap between water pump sprocket and timing chain, by carefully turning crankshaft pulley counterclockwise until timing chain loosens on water pump sprocket. Remove three water pump bolts.





b. Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: approx. 50 mm (1.97 in)] into water pump upper and lower bolt holes until they reach timing chain case. Remove water pump.

CAUTION:
- Place a suitable shop cloth below the water pump housing to prevent any engine coolant from dripping into the timing chain case.
- Pull water pump straight out while preventing vane from contacting socket in installation area.
- Remove water pump without causing sprocket to contact timing chain.
c. Remove M8 bolts and O-rings from water pump.

CAUTION:
- Do not disassemble water pump.
- Do not reuse O-rings.

INSPECTION AFTER REMOVAL





- Visually check that there is no significant dirt or rusting on the water pump body and vane.
- Check that there is no looseness in the vane shaft, and that it turns smoothly when rotated by hand.
- If the water pump does not perform properly, replace the water pump assembly.

INSTALLATION
1. Install new O-rings to water pump.

NOTE:





- Apply engine oil to O-rings.
- Locate O-ring with white paint mark to engine front side.





2. Hold timing chain to the side (Backward Black Arrow) and install water pump ((Black Arrow).

CAUTION:
Do not allow timing chain case to pinch O-rings when installing water pump.
- Make sure that timing chain and water pump sprocket are engaged.
- Tighten water pump bolts alternately and evenly.
3. Remove dust and foreign material completely from installation area of timing chain tensioner (primary) and rear timing chain case.





4. Turn crankshaft pulley approximately 20� clockwise so that timing chain on the timing chain tensioner (primary) side is loose.
5. Install timing chain tensioner (primary) with its stopper pin inserted.

CAUTION:
Be careful not to drop bolts inside timing chain case.





6. Remove stopper pin.
- Make sure again that timing chain and water pump sprocket are engaged.
7. Install chain tensioner cover and water pump cover.





a. Before installing, remove all traces of old liquid gasket from mating surface of water pump cover and chain tensioner cover using scraper. Also remove traces of old liquid gasket from the mating surface of front timing chain case.





b. Apply a continuous bead of liquid gasket, to mating surface of chain tensioner and water pump cover, using Tool.






Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Attaching should be done within 5 minutes after coating.
c. Tighten bolts to specified torque. Exploded View.





8. Install water drain plug (front) (1) on water pump side of cylinder block.
- Apply liquid gasket to the thread of water drain plug (front) (1).
Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.






9. Installation of the remaining components is in the reverse order of removal.
- After installation refill engine coolant and check for leaks. Service and Repair and Initial Inspection and Diagnostic Overview.

CAUTION:
Do not spill coolant in the engine compartment. Use a shop cloth to absorb coolant.
- After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioner. The engine may produce a rattling noise.
This indicates that air still remains in the chamber and is not a matter of concern.

INSPECTION AFTER INSTALLATION
- Check for engine coolant leaks. Initial Inspection and Diagnostic Overview.
- Start and warm up engine. Visually check for coolant leaks. Repair as necessary.
- Check and adjust engine coolant level.