Water Pump: Service and Repair

REMOVAL
1. Remove air cleaner duct.
2. Remove air cleaner, Manifold Absolute Pressure (MAP) meter and intake air connector pipe assembly.
3. Remove drive belt, fan, fluid coupling assembly and water pump pulley, refer to Drive Belts, Mounts, Brackets and Accessories.
4. Remove radiator assembly.
5. Remove timing belt, refer to Timing Components.
6. Remove idler pulley, refer to Timing Components.
7. Remove water inlet and thermostat.

8. Remove water bypass outlet and No.1 water bypass pipe as follows:
(a) Remove the 2 bolts, water bypass outlet and No.1 water bypass pipe.
(b) Remove the 3 O-rings from the water bypass outlet and No.1 water bypass pipe.
9. Remove alternator.
10. Remove water pump as follows:

(a) Remove the bolt, and disconnect the engine wire bracket.
(b) Remove the bolt, and disconnect the clamp bracket (for crankshaft position sensor connector).

(d) Remove the 6 bolts, water pump and gasket.
(e) Remove the drain hose.
(f) Remove the O-ring from the cylinder block.

INSTALLATION
1. Install water pump to block as follows:

(a) Install a new O-ring to the cylinder block.
(b) Install the drain hose.

(c) Install a new gasket to the water pump.
(d) Connect the water pump to the water bypass pipe. Do not install the nut yet.

(e) Install the water pump with the 2 bolts (A) and 4 bolts (B), then tighten to 21 Nm (210 kg.cm, 15 ft.lb).

NOTE: Hand tighten the (A) bolts first.

(f) Install the 2 nuts holding the No.2 water bypass pipe to the water pump, tighten to 21 Nm (210 kg.cm, 15 ft.lb).
(g) Install the clamp bracket (for crankshaft position sensor connector) with the bolt.
(h) Install the engine wire bracket with the bolt.
2. Install alternator.
3. Using new O-rings, install no.1 water bypass pipe and water bypass outlet, then tighten to 8.8 Nm (90 kg.cm, 78 in.lb).
4. Install thermostat and water inlet.
5. Install idler pulley, refer to Timing Components.
6. Install timing belt, refer to Timing Components.
7. Install radiator assembly.
8. Install water pump pulley, fan, fluid coupling assembly and drive belt, refer to Drive Belts, Mounts, Brackets and Accessories.
9. Install air cleaner, MAP meter and intake air connector pipe assembly.
10. Install air cleaner duct.
11. Fill with engine coolant.
12. Start engine and check for leaks.
13. Check automatic transmission fluid level.
14. Road test, check for abnormal noise, shock, slippage, correct shift points and smooth operation.
15. Recheck engine coolant level.