Water Pump: Service and Repair

COMPONENTS FOR WATER PUMP REMOVAL AND INSTALLATION





WATER PUMP REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE GENERATOR (See page CH-8)





4. REMOVE INTAKE MANIFOLD STAY
- Remove the bolt, nut and intake manifold stay.

5. REMOVE WATER INLET PIPE
(a) Disconnect the following hoses:





(1) Water inlet hose
(2) Heater inlet hose
(3) Water bypass hose





(b) Remove the bolt, water inlet pipe and 0-ring.

6. REMOVE OIL DIPSTICK GUIDE AND GENERATOR ADJUSTING BAR
(a) Remove the oil dipstick.
(b) Remove the mounting bolt of the dipstick guide clamp and generator adjusting bar.





(c) Pull out the dipstick guide. Plug the guide installation hole of the oil pump.
(d) Remove the 0-ring from the dipstick guide.





7. REMOVE WATER PUMP
- Remove the bolt, 2 nuts and water pump.

WATER PUMP INSPECTION
INSPECT WATER PUMP BEARING





- Check that the water pump bearing operation is not rough or noisy.
- If necessary, replace the water pump assembly.

WATER PUMP INSTALLATION
1. INSTALL WATER PUMP





(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the contact surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.





(b) Apply seal packing to the water pump groove.
Seal packing: Part No.08826-00100, THREE BOND 1282B or equivalent

- Install a nozzle that has been cut to a 2-3 mm (0.08-0.12 in.) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
- Do not pour in any coolant until at least 2 hours after installation is completed.





(c) Install the water pump with the bolt and 2 nuts.

Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)

2. INSTALL OIL DIPSTICK GUIDE AND GENERATOR ADJUSTING BAR





(a) Install a new 0-ring to the dipstick guide.
(b) Apply soapy water to the 0-ring.
(c) Push in the dipstick guide, and install it with the mounting bolt of the generator adjusting bar and dipstick guide clamp.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

(d) Install the oil dipstick.

3. INSTALL WATER INLET PIPE




(a) Install a new 0-ring to the water inlet pipe.
(b) Apply a little soap and water to the 0-ring.
(c) Insert the water inlet pipe to the water pump.





NOTICE: Installing the water inlet pipe at an angle or twisting it during installation will cause pinching or tearing of the 0-ring.





(d) Install the water inlet pipe with the bolt.

Torque: 6.4 N.m (75 kgf.cm, 54 in.lbf)

(e) Connect the following hoses:




(1) Water inlet hose
(2) Heater inlet hose
(3) Water hose

4. INSTALL INTAKE MANIFOLD STAY





- Install the intake manifold stay with the bolt and nut.

Torque: 17 N.m (175 kgfcm, 13 ft.lbf)

5. INSTALL GENERATOR
6. INSTALL RH ENGINE UNDER COVER
7. REFILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR LEAKS