09200-05560 PUMP ASSY, INJECTI Denso Cross

Start By:a. remove radiator 1. Remove the four bolts and remove fan blade (1) and extension. 2. Loosen bolts (2) and remove fan belt (4). Loosen clamps (3) and disconnect the two hoses. Remove nut (5) from water pump fan pulley (6). 3. Install tooling (A) and remove fan pulley (6). 4. Remove four bolts (7) and remove the water pump and gasket. At the time of assembly, tighten nut (5) to the torque of 80 N m (60 lb.ft.) Install in the reverse order.Disassemble Water Pump
Start By:a. remove water pump 1. Remove key (1) from the shaft. 2. Remove pump housing (2) from the rear housing. 3. Remove snap ring (3) with tool (A). 4. Put the water pump housing in position on a press. Install tool (B) and remove the shaft assembly from the impeller and water pump housing. 5. Remove seals (4) from the water pump housing if they are damaged. 6. Put shaft assembly (5) in position in a press. Install tool (B) and remove bearings (6) and spacer (7) from the shaft.Assemble Water Pump
1. Put one of the shaft's bearings in position in a press. Make sure there is support for the inner race of the bearing. Push shaft (1) on to bearing (2). 2. Install spacer (4) on the shaft. Put second bearing (3) in position and push the shaft on to it. 3. Install seal (6) and flange (5) in the water pump housing. 4. Put 2S3230 Bearing Lubricant on the bearings. Put the water pump housing in position on a press and install shaft assembly (7) in the housing. 5. Install snap ring (8) over the bearings with tool (A). 6. Install the water seal in the housing with tooling (B). 7. Install seal (9) on the shaft assembly. 8. Install impeller (10) on the shaft with tooling (C) and a press. The clearance between the impeller blade and pump body must be 0.30 to 0.81 mm (.012 to .032 in). 9. Install a new gasket on water pump housing (12). Install housing (12) on the rear housing with nuts (11) that hold it. 10. Install key (13) in the shaft.End By:a. install water pump