3.  Install retaining nut of the engine 

water inlet pipe joint 
components. 

Torque:10Nm(Metric) 7.4lb-ft(English 
system) 

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4.  Install components from water 

outlet pipe of radiator to engine 
water inlet pipe joint. 

5.  Tighten the radiator outlet pipe 

clamp. 

6.  Fill engine coolant. 

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2.8.8.5 Replacement of Water Pump 

4G20/4G24engine : 

Dismantlement Procedure 

1.  Disconnect the battery negative 

electrode cable. Refer to 2.12.6.1 
Battery Disconnection.

 

2.  Refer to 2.8.8.1 Engine Coolant 

Discharge and Filling to 
discharge engine coolant. 

3.  Dismantle the drive belt. 

Refer to 2.6.8.3 
Replacement of Drive Belt.

 

4.  Refer to 2.8.8.4 "Replacement of 

Thermostat" to dismantle the 
thermostat component. 

5.  Dismantle the fixing bolts of 

water pump belt pulley.

 

6.  Remove the fixing bolt for the 

water pump. 

7.  Dismantle the water pump belt 

pulley. 

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8.  Dismantle the fixing bolts of 

water pump. 

9. Dismantle the water pump 

assembly. 

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580

10. Dismantle Heater Outlet Pipe 

retaining screws. 

11.  Dismantle the Heater Outlet Pipe.

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12. Dismantle the fixing bolts of 

water pump housing. 

13. Dismantle the water pump 

housing. 

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Water Pump Inspection: 

Warning: Refer to "Warning on 
Safety Protective Eyewear" in 
"Warning and Precautions". 

1.  Inspect whether the water pump 

housing is cracking and leaking. 

2.  Inspect whether the water pump 

bearing has a gap or abnormal 
sound. 

3.  Inspect for the integrity of the 

water pump belt pulley.  If 

the 

water pump is damaged, replace 
the whole set of the pump 
housing subassembly. 

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581

Installation Procedure: 

1.  Clean the water pump housing 

O-ring mounting groove and 
mating surface. 

2.  Install the drainage valve. 

3.  Install the pump assembly to the 

pump housing and tighten the 
fixing bolts. 

4.  Install the inlet seats for the 

thermostat and the engine. 

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5.  Install new water pump housing 

O-ring. 

Note: The water pump housing 
O-ring is a single used part and must 
be replaced with new parts after 
removal. 

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6.  Install the water pump housing 

subassembly and five mounting 
bolts, but do not tighten at this 
stage. 

7.  Tighten the fixing bolts of water 

pump according to the sequence 
as shown in the figure. 

Torque: 32-38 N.m (Metric) 23.6-28.0 
lb-ft (English system) 

1

5

3

2

4

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