Water Pump: Service and Repair

REMOVAL OF WATER PUMP






1. DRAIN COOLANT
Open the radiator and engine drain cocks and allow the coolant to drain into a clean container.
2. REMOVE PS DRIVE BELT (4A-GE ONLY)
3 REMOVE ALTERNATOR DRIVE BELT






(a) Loosen the water pump pulley bolts.






(b) Loosen the lock bolt and pivot nut.
(c) Move the alternator fully right, and remove the drive belt.
4. REMOVE PS DRIVE BELT (4A-C ONLY)
5. REMOVE WATER PUMP PULLEY
(d) Remove the four bolts and pump pulley.
6 REMOVE WATER INLET PIPE






(a) Disconnect the water inlet and water by-pass hoses from the inlet pipe.






(b) Remove the two nut and clamp bolts.
(c) Remove the water inlet pipe and 0-ring.

7. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK






Remove the mounting bolt and pull out the oil dipstick guide and gauge.

NOTE: After pulling out the oil dipstick guide, be sure to plug the oil pump body hole.

8. (4A-C)
REMOVE NO.1 TIMING BELT COVER (4A-GE)
REMOVE NO.3 AND NO.2 TIMING BELT COVERS AND GASKETS
9. REMOVE WATER PUMP






Remove the three bolts and water pump.

CAUTION: Be careful not to get coolant on the timing belt.

INSTALLATION OF WATER PUMP

1. INSTALL WATER PUMP






Place the water pump 0-ring on the block and install the pump with three bolts. Torque the bolts.

Torque: 150kg-cm (11 ft-lb, 15 N.m)

2. (4A-C)
INSTALL NO.1 TIMING BELT COVER (4A-GE)
INSTALL NO. 2 AND NO.3 TIMING BELT COVERS WITH GASKETS






3. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
(a) Install a new 0-ring on the oil dipstick guide.
(b) Apply small amount of engine oil to 0-ring.
(c) Push in the oil dipstick guide with the 0-ring.
(d) Install the mounting bolt.






4. INSTALL INLET PIPE
(a) Install the inlet pipe and a new 0-ring to the water pump with the two nuts.
(b) Install the inlet pipe clamp bolt.






(c) Connect the water inlet and water by-pass hoses to the inlet pipe.

5. TEMPORARILY INSTALL WATER PUMP PULLEY
Install the water pump pulley and temporarily tighten the four bolts.

6. INSTALL PS AND/OR A/C DRIVE BELT (4A-C ONLY)
7. INSTALL ALTERNATOR DRIVE BELT
(a) Place the drive belt the each pulley and set up the drive belt.






(b) Tighten the four bolts of the water pump pulley.

8. INSTALL PS DRIVE BELT (4A-GE ONLY)
9. ADJUST DRIVE BELT TENSION
Using a belt tension gauge, adjust the drive belt tension. Belt tension gauge: Nippondenso Borroughs BTG-20 (95506-00020) or Borroughs No. BT-33-73F






Drive belt tension:
4A-C (Alternator)
New belt 160 ± 20 lb Used belt 130 ± 20 lb
4A-C (PS)
New belt 125 ± 25 lb Used belt 80 ± 20 lb
4A-GE
New belt 175 ± 5 lb Used belt 115 ± 20 lb

NOTE:
"New belt" refers to a belt which has been used less than 5 minutes on a running engine.
"Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in the ribbed grooves.
10. REFILL WITH COOLANT (See page CO-4)
11. START ENGINE AND CHECK FOR LEAKS