Removal and Installation

Water Pump: Removal and Installation

WARNING:

Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.

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 hose and clamp securely, then check for leaks.

Removal

1) Drain engine coolant from radiator. Refer to [Engine Cooling Fan: Removal and Installation (Motor driven type)] Initial Inspection and Diagnostic Overview.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on timing chain and drive belt.

2) Remove water drain plug (front) (1) on the water pump side of the cylinder block.





3) Remove coolant reservoir hose from the radiator.
4) Remove engine cooling fan (Motor driven type). Refer to Motor Driven Type.
5) Remove engine cooling fan (Crankshaft driven type) and fan bracket. Refer to [Engine Cooling Fan: Removal and Installation (Crankshaft driven type)] Crankshaft Driven Type.
6) Set No. 1 cylinder at TDC.
- Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).





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











8) Remove timing chain tensioner (primary) as follows:
a) Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).





b) Insert plunger into tensioner body by pressing slack guide (2).
c) Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove (3).
d) Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.





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






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

9) Remove water pump as follows:
a) Remove three water pump bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum.





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. Then, alternately tighten each bolt for a half turn, and pull out 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

- Check for badly rusted or corroded water pump body assembly.
- Check for rough operation due to excessive end play.





- Replace water pump, if necessary.

Installation

1) Install new O-rings to water pump.

CAUTION:
Do not reuse O-rings.

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 () and install water pump ().






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. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

CAUTION:
- Installation should be done within 5 minutes after applying liquid gasket.
- Do not fill the engine with oil for at least 30 minutes after the components are installed to allow the sealant to cure.

c) Tighten bolts to specified torque. Refer to [Water Pump: Exploded View] 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).
Use Genuine RTV Silicone Sealant or equivalent. Refer to [Recommended Chemical Products and Sealants] 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. Refer to [Changing Engine Coolant] Service and Repair and [Engine Coolant: System Inspection] 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. Refer to [Engine Coolant: System Inspection] Initial Inspection and Diagnostic Overview.
- Start and warm up engine. Visually check for engine coolant leaks. Repair as necessary.