Usage:
1. Drain the coolant from the cooling system.
2. Disconnect the water pump inlet from the radiator.
3. Remove the bolts and retainers from both ends of tube (1). Remove tube (1) from the engine.
4. Fasten a hoist to water pump (3). Remove all of bolts (2) and (4) that hold the pump to the engine. Remove water pump (3) from the engine. The weight of pump (3) is 39 kg (85 lb.).
Install Water Pump
1. Make sure the gasket for the water line adapter and the O-ring seal on the pump are in position. Put clean engine oil on the O-ring seal. Fasten a hoist to water pump (1), and put water pump (1) in position on the engine. Make sure the splines on the pump shaft are correctly engaged. Install the bolts to hold the pump in position.
2. Make sure the O-ring seals on both ends of tube (2) are in position, and put clean engine oil on the seals. Put tube (2) in position, and install the retainers and bolts to hold the tube in position on the engine.
3. Connect the water pump inlet to the radiator.
4. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.
Disassemble Water Pump
START BY:
a. remove water pump
1. Remove elbow (1) from housing assembly (2). Remove the O-ring seal from elbow (1).
2. Remove O-ring seal (5) from the back of housing assembly (2).
3. Remove washer (4) that holds shaft assembly (3) in housing assembly (2).
4. Remove cover (6) from housing assembly (2). Remove the O-ring seal from cover (6).
NOTE: Later model water pumps use a nut to hold the impeller to the shaft instead of bolt (8).
5. Loosen bolt (8) and the washer that hold impeller (7) to the pump shaft. Use tooling (A) to loosen impeller (7) from the end of the pump shaft. Remove tooling (A), bolt (8), the washer and impeller (7) from the pump shaft and housing assembly (2).
6. Remove spring (10) from seal assembly (9) and shaft assembly (3).
7. Use a soft hammer, and push shaft assembly (3) out of seal assembly (9) and housing assembly (2). Remove seal assembly (9) from housing assembly (2).
8. Remove ceramic seal (11) from the rubber ring. Remove the rubber ring from housing assembly (2).
9. Remove seal (12) from the back of housing assembly (2).
Assemble Water Pump
1. If necessary, make a replacement of the two filters in the pump housing at location (1).
2. If necessary, make a replacement of plug (2) and the seal.
3. Use tool group (A) to install the seal in the housing assembly. Make sure the lip of the seal is toward the outside as shown. Put clean engine oil on the lip of the seal.
4. Install shaft assembly (3) in housing assembly (4). Install washer (5) and the bolts to hold shaft assembly (3) in position.
| NOTICE |
|---|
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly. |
5. Put ceramic seal (6) in position in the rubber ring. Use hand pressure and the tool (which is with the replacement seal) to install the ceramic seal.
6. Remove the spring from seal assembly (7). Use hand pressure and the tool (which is with the replacement seal) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact.
7. Install spring (8) on the carbon seal assembly.
8. Put impeller (9) in position on the pump shaft as shown.
9. Install washer (11) and belt (10). Tighten bolt (10) to a torque of 90 ± 15 N·m (66 ± 11 lb.ft.). Hit the bolt with a hammer, and tighten it again to a torque of 90 ± 15 N·m (66 ± 11 lb.ft.).
NOTE: Later model water pumps use a nut on the shaft assembly instead of bolt (10). Tighten the nut to a torque of 200 ± 25 N·m (148 ± 18 lb.ft.).
10. Make sure the studs for cover (12) are tightened to a torque of 27 ± 4 N·m (20 ± 3 lb.ft.) in the pump housing.
11. Put clean engine oil on O-ring seal (13), and install it on cover (12). Put cover (12) in position, and install the nuts to hold it to the pump housing.
12. Put clean engine oil on the O-ring seal, and install it in elbow (14). Put elbow (14) in position on housing assembly (4), and install the bolts to hold the unit together.
13. Put clean engine oil on the O-ring seal, and install it on the back of housing assembly (4).
END BY:
a. install water pump