Water Pump and Water Temperature Regulator - Remove and Install


Water Pump

Removal Procedure

Remove: 
- the fan and the fan pulley. Drain the coolant from the cooling system into a suitable container for storage or disposal. Loosen the hose clamps and remove the hose (not shown) from the water pump inlet.


1-front cover, 2-joint, 3-water pump, 4-setscrews, 5-joint, 6-cover, 7-setscrews

- the setscrews (4). The setscrews are three different lengths. Note the positions of the different setscrews.
- the water pump (3) from the front cover (1). If necessary, tap the water pump with a soft hammer in order to loosen the water pump.
- the joint (2). Discard the joint. If necessary, remove the cover (6) from the water pump. Follow Steps to remove the cover.
- the two setscrews (7).
- the cover (6).
- the joint (5). Discard the joint.

Installation Procedure

Ensure that the water pump is clean and free from wear or damage. If necessary, replace the water pump.


1-front cover, 2-joint, 3-water pump, 4-setscrews, 5-joint, 6-cover, 7-setscrews

If necessary, install the cover (6) to the water pump (3). Clean the joint face of the cover (6). Position a new joint (5) on the water pump (3).
Install: 
- the cover (6) to the water pump (3).
- the two setscrews (7) to the cover (6). Tighten the setscrews finger tight. Clean the joint face of the front cover (1).


- Tooling A in position (X). Use Tooling in order to align the new joint (2) to the front cover (1). 
- the joint to the front cover. Align the water pump (3) to Tooling. 
- the water pump to the front cover (1). Ensure that the gear of the water pump and the gear of the fuel injection pump mesh.
- the setscrews (4). Refer to Illustration. Tighten the setscrews finger tight. Ensure that all setscrews of different lengths are installed in the correct positions. Remove Tooling and install the two remaining setscrews (4).


Tighten the setscrews (4) and (7) in the sequence to a torque of 22 N·m (16 lb ft).
- the hose (not shown) to the water pump inlet. Tighten the hose clamps.
Fill the cooling system with coolant.
- the fan and the fan pulley.

Water Temperature Regulator

Removal Procedure

Drain the coolant from the cooling system to a level below the water temperature regulator, into a suitable container for storage or for disposal.
Loosen the hose clamps from the upper radiator hose and disconnect the upper radiator hose from the water temperature regulator housing (2).


Remove:
- the two setscrews (1) from the water temperature regulator housing (2).
- the water temperature regulator housing (2) from the cylinder head. Note the orientation of the water temperature regulator housing.


- the O-ring seal (3) from the water temperature regulator housing (2). Discard the O-ring seal.

Installation Procedure

Ensure that all components of the water temperature regulator housing (2) are clean and free of wear or damage. Check the water temperature regulator for correct operation.
If any components of the water temperature regulator housing are worn or damaged, the complete assembly must be replaced.

If the original water temperature regulator housing is installed, position a new O-ring seal (3) into the groove in the water temperature regulator housing (2). A new water temperature regulator housing is supplied with a new O-ring seal.
Install:
- the water temperature regulator housing (2) to the cylinder head. Ensure the correct orientation of the water temperature regulator housing.

- the setscrews (1). Tighten the setscrews (1) to a torque of 44 N·m (32.5 lb ft). Connect the upper radiator hose and tighten the hose clamps. Fill the cooling system to the correct level.