Coolant pump — removal and installation

OHC engines

Withdrawal

1. Disconnect the ground wire from the battery and drain the liquid from the cooling system.

2. Remove fan with clutch.

3. Remove V-belt.



4. Unscrew the bolts and remove the pulley from the coolant pump.

5. Disconnect the flexible pipe leading to the heater from the coolant pump.

6. Remove flexible coolant line between coolant pump and radiator.

7. Unscrew the three mounting bolts and remove the toothed belt cover.

8. Remove the three coolant pump mounting bolts and remove the pump completely.

Repair

1. Remove the pump shaft assembly with seal, precision bearing and rotor from the pump housing.

2. Remove the seal from the pump shaft and remove the precision bearing from the pump housing.

3. Using a ring and a shank of the appropriate diameter and length, move the pump pulley hub on the pump shaft so that the end of the shaft protrudes 1.5 mm above the outer surface of the hub.

4. Install a new seal on the pump shaft and into the recess in the housing.

5. Install its rotor on the pump shaft so that the gap between its blades and the pump housing is 0.8 mm.

Installation

1. Clean the connection surfaces of the pump housing and engine block.

2. Install the pump with a new gasket on the cylinder block.

3. Install the toothed belt guard.

4. Connect the flexible pipes connecting the pump to the radiator and heater to the coolant pump.

5. Install fan.

6. Adjust the tension of the V-belt.

7. Fill the cooling system, connect the battery and check the tightness and function of the cooling system. Top up the coolant level if necessary.

DOHC engines

Elements of the DOHC engine cooling system

Withdrawal

1. Remove ground wire from battery.

2. To improve access to the pump on engines with a fuel injection system, remove the air intake, pressure chamber and air filter.

3. Drain the coolant from the cooling system.

4. Remove drive belt.

5. Unscrew the 4 bolts securing the water pump pulley and remove the pulley.



6. Substitute a suitable container under the pump, unscrew the 5 screws securing the pump and remove the pump.




7. Remove sealing ring from pump (indicated by an arrow). The water pump O-ring must be replaced.

Installation

Installation is made in sequence, return to removal.

Connecting Hoses to the DOHC Engine Water Pump Housing

On models prior to May 1990, the coolant hoses were connected to the water pump housing as shown.

On models from May 1990 heater hose (A) and expansion tank hose (IN) replaced in places.

If the hoses were removed on earlier models, they must be reconnected as on later models, i.e. connect the heater hose to port B and the expansion tank hose to port A. This will reduce heater noise due to air in the system.

V6 engines

1. Disconnect the ground wire from the battery and drain the liquid from the cooling system.

2. Remove fan with clutch.

3. Remove V-belt.

4. Unscrew the bolts and remove the pulley from the coolant pump.

5. Disconnect lower radiator hose and heater hose from thermostat housing.

6. Unscrew the three bolts securing the thermostat housing to the water pump.

7. Remove housing and thermostat.



8. Unscrew the twelve bolts and remove the water pump. On some models it is necessary to remove the crankshaft pulley and vibration damper to gain access to the lower pump mounting bolts.