Water Pump: Service and Repair
Removal and InstallationCO-23 Component:
CAUTION:
^ When removing water pump assembly, be careful not to get engine coolant on drive belts.
^ 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 using the radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service tool).
REMOVAL
1. Remove engine room cover (RH and LH).
2. Remove air duct (inlet) and air cleaner case assembly.
3. Remove front engine undercover with power tool.
4. Remove drive belts.
5. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when the engine is cold.
^ Never spill engine coolant on drive belts.
6. Remove water drain plug (front) on water pump side of cylinder block to drain engine coolant from engine inside.
7. Remove chain tensioner cover and water pump cover from front timing chain case.
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
8. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt.
CAUTION: Be careful not to drop mounting bolt inside timing chain case.
b. Loosen upper mounting bolt slowly, and then turn chain tensioner (primary) on the mounting bolt so that plunger is fully expanded.
NOTE: Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary).
c. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.
d. Remove upper mounting bolt, and then remove timing chain tensioner (primary).
CAUTION: Be careful not to drop mounting bolt inside timing chain case.
9. Remove water pump as follows:
a. Remove three water pump mounting 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 (0.0492 in) length: approx. 50 mm (1.97 in)] into water pumps upper and lower mounting bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump.
CAUTION:
^ Pull 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: Never disassemble water pump.
INSPECTION AFTER REMOVAL
^ Check for badly rusted or corroded water pump body assembly.
^ Check for rough operation due to excessive end play.
^ If anything is found, replace water pump.
INSTALLATION
1. Install new O-rings to water pump.
^ Apply engine oil and engine coolant to O-rings as shown in the figure.
^ Locate O-ring with white paint mark to engine front side.
2. Install water pump.
CAUTION: Never allow cylinder block to nip O-rings when installing water pump.
^ Check timing chain and water pump sprocket are engaged.
^ Insert water pump by tightening mounting bolts alternately and evenly.
3. Install timing chain tensioner (primary) as follows:
a. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.
b. Pull plunger stopper tab up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger.
NOTE: Plunger stopper tab and lever are synchronized.
c. Push plunger into the inside of tensioner body.
d. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet.
e. To secure lever, insert stopper pin through hole of lever into tensioner body hole.
^ The lever parts and the tab are synchronized. Therefore, the plunger will be secured under this condition.
NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
f. Install timing chain tensioner (primary).
^ Remove dust and foreign material completely from backside of timing chain tensioner (primary) and from installation area of rear timing chain case.
g. Remove stopper pin.
h. Check again that timing chain and water pump sprocket are engaged.
4. Install chain tensioner cover and water pump cover as follows:
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 with tube presser (commercial service tool) to mating surface of chain tensioner cover and water pump cover. Use Genuine RTV Silicone Sealant or equivalent.
CAUTION: Attaching should be done within 5 minutes after coating.
c. Tighten mounting bolts.
5. Install water drain plug (front) 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.
6. Install in the reverse order of removal for remaining parts.
^ 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 chain tensioner. 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 leaks of engine coolant using the radiator cap tester adapter (commercial service tool) and the radiator cap tester (commercial service tool). Refer to, "Inspection". System Inspection
^ Start and warm up the engine. Visually check that there is no leaks of engine coolant.