Water Pump: Service and Repair

REMOVAL AND INSTALLATION

Fig. 2 Balance shaft drive & camshaft drive exploded view.:

1. Drain coolant from cold engine by setting heater control lever to warm position and unscrew drain plug.
2. Disconnect negative battery cable.
3. Remove air cleaner assembly.
4. Remove lower radiator hose.
5. Remove accessory drive belts.
6. Remove upper and lower front timing belt covers.

TDC Mark 16 Valve:

TDC Mark:

7. Rotate engine to TDC cylinder #1. Also check TDC mark on flywheel.

Lower Balance Shaft Timing Mark:

Upper Balance Shaft Timing Mark:

8. Ensure alignment of balance shaft marks.

Distributor Console:

9. Remove distributor cap, distributor rotor, distributor protective cover, and distributor cap console.

Timing Belt Arrangement:

10. Loosen balance shaft tensioning rollers and remove balance shaft drive belt.
11. Remove balance shaft drive gears.
12. Loosen timing belt tensioning roller and remove timing belt.

CAUTION: Never continue to rotate engine if the toothed camshaft belt is not fitted of has not been tightened since this may to valve damage.

13. Remove crankshaft pulleys and drive gears.
14. Remove rear timing cover.

Water Pump Assembly:

15. Remove water pump retaining bolts and remove water pump.
16. Exchange parts on water pump as necessary.

NOTE: Check the condition of the balance shaft and the camshaft seals. Replace as necessary.

INSTALLATION
- Scrape gasket as required.
- Reinstall water pump.
- Reinstall rear timing cover, torque bolts to 8 Nm (6 ft lbs).
- Reinstall crankshaft and timing gears.

Pre-tensioning the hydraulic toothed belt tensioner
- After removal, the hydraulic toothed belt tensioner must be pre-tensioned in a vise. Fit aluminum jaws into vise. Insert the crank- shaft bolt washer (pan no. 944.102.210.02) at the lower section of the tensioner housing to protect the tensioner bottom.

CAUTION: Do not apply pressure to inner surface of the tensioner housing. Press only on outer edge of the tensioner housing.

- Tighten vise slowly until resistance is felt. Wait for a couple of seconds and then tighten somewhat more.
- Continue to tighten in this order until the push rod housing bores are flush with each other and the push rod may be locked with Special Tool 9530 (upper Fig.).

Timing Belt Arrangement:

- Reinstall timing belt in the following sequence:
- Crankshaft drive gear
- Install and lock tensioning lever (Preload the lock ring, replace if required)
- Camshaft drive pinion
- Coolant pump recirculation gear
- Tensioning pulley
- Install hydraulic toothed belt tensioner and rotate Special Tool 9530 to pull tool out. Rotate crankshaft by two turns and check TDC marks on flywheel and camshaft drive, respectively.
- Ensure alignment of balance shaft marks. Install balance shaft belt.
- Using special tool 9201, tighten balance shaft belt to 2.7 +/- 0.3, Checking and Adjusting Tension
- Rotate engine one full revolution and recheck belt tension.
- Finish installation by reversing removal procedures.
- Replace drain plug. Remove bleeder plugs. Slowly add coolant until fluid level remains at the "max" mark in the expansion tank.
- Start and run engine at fast idle until radiator fan switches on and off adding coolant as necessary.
- When fluid leaving bleeder is free from air bubbles replace bleeder plug.
- Ensure proper coolant level in expansion tank.