0390981 JOHNSON PISTON, Std.

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Loosen the hose clamps and remove the hose from the water pump inlet.
Illustration 1 g01263054
Typical example
Remove bolts (4) . The bolts are different lengths. Note the positions of the different bolts.Note: Do not remove bolts (7) at this time.
Remove water pump (3) from front cover (1) .Note: If necessary, tap the water pump with a soft hammer in order to loosen the water pump.
Remove gasket (2) .
If necessary, remove cover (6) from the water pump. Follow Steps 6.a through 6.c in order to remove the cover.
Remove bolts (7) .
Remove cover (6) .
Remove gasket (5) .Disassembly Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-7600     Slide Hammer Puller     1    
B     -     Drill Bit 3 mm (0.118 inch)     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 2 g03367454
Typical example
Remove bolts (2) from cover (3) of the assembly of water pump (1) . Remove gasket (4) (not shown) and cover (3) .Note: All of the other bolts are removed during the removal of the water pump.
Illustration 3 g03367455
Typical example
Use Tooling (B) in order to drill 12 holes between the existing holes in the impeller (5) . Break pieces from the impeller (5) .
Install a suitable two legs puller (6) onto the remaining boss of impeller (5) .
Use the suitable two legs puller (6) in order to remove the remaining boss of impeller (5) .
Illustration 4 g03367456
Breaking coolant seal (10) will be necessary in order to remove the coolant seal from water pump (1) .
Use Tooling (B) in order to drill three holes that are equally spaced into coolant seal (10) . The holes should be drilled into the face of coolant seal (10) that would have faced impeller (5) .
Use Tooling (A) in order to remove coolant seal (10) off the shaft (11) . Alternate the position of Tooling (A) from one hole to another. Alternating the position of Tooling (A) will allow the coolant seal to be easily removed from water pump (1) .
If necessary, remove the center sleeve of the coolant seal from the shaft with a suitable extractor.
Remove outer circlip (14) .
Remove inner circlip (13) .
Support machined Face (X) of water pump (1) on a suitable support. Press on the shaft (11) until the gear (12) and the bearing (9) are free from the shaft.
Discard shaft (11) , bearing (9) . Remove the gear (12) through the side of water pump (1) .
Insert a suitable mandrel onto oil seal (8) and press the oil seal out of water pump (1) .
The oil seal (8) can be removed through the side of water pump (1) after the seal has been released from the water pump.
Support the machined Face (Y) of water pump (1) on a suitable support.
Use a suitable mandrel to press needle bearing (7) out of water pump (1) .Assembly Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 5 g03367456