Tools & supplies
- Metric socket set (8–24 mm), deep sockets, extensions
- Torque wrench (range to at least 200 Nm)
- Breaker bar
- Ratchet and swivel
- Impact gun (optional; don’t use for final torque)
- Pulley/gear puller (suitable for fan pulley)
- Fan clutch wrench or large spanner (if engine-mounted fan)
- Screwdrivers, pliers, hose pliers
- Gasket scraper / razor blade, wire brush
- Seal puller / pick
- Funnel and coolant drain pan
- Jack and rated jackstands or vehicle lift; wheel chocks
- Engine support or hoist (if engine mounts must be loosened)
- Clean rags, solvent/degreaser
- New water pump (OEM Hino 700 part for the engine fitted), new gasket(s)/O‑ring(s), new coolant, new drive belt(s) (recommended), new hose clamps (recommended)
- RTV sealant (if specified by manual) and threadlocker (if specified)
- Protective gloves, eye protection

Safety first
- Work on a flat surface, chock wheels, engage parking brake.
- Allow engine to cool completely. Hot coolant is under pressure — never open radiator cap while hot.
- Disconnect negative battery terminal.
- Support vehicle securely with jackstands or use a lift. Use an engine hoist/support if engine mounts must be loosened.
- Capture coolant; avoid skin/eye contact and environmental release.
- Use proper PPE.

Overview & checks before starting
- Confirm exact engine model in the Hino 700 (J08E/A09C/E13 etc.) and obtain the workshop manual for torque specs and any model-specific steps.
- Inspect pump for shaft play, leaks, corrosion; measure belt condition and note if fan clutch is oily/worn — replace as needed.
- Order parts: water pump assembly, pump gasket/O‑ring, drive belt(s), coolant, hose clamps, possibly thermostat if old.

Step-by-step procedure
1. Prepare and drain
- Park, chock wheels, disconnect negative battery.
- Remove engine covers/obstructions to access front of engine.
- Put drain pan under radiator. Open drain cock and drain coolant. Remove radiator cap only when cool.

2. Remove fan/fan shroud and accessories
- Remove fan shroud (unbolt) and move out of the way.
- Remove engine-driven fan: hold fan hub with fan wrench and remove nut or use fan clutch tool depending on setup. If fan is attached to water pump pulley, remove entire fan assembly.
- If there is a viscous fan clutch, support it and remove bolts/nut as per manual.
- Remove accessory drive belts (alternator, A/C, power steering) and note routing. Replace belts if worn.

3. Remove pulley(s)
- Remove the water pump pulley or timing cover/pulley as required by engine layout.
- Use pulley/gear puller to pull the pulley if it won’t slide off. Use a gentle, even pull to avoid bending the pulley.
- If pump is behind timing gears/cover (some Hino engines), follow manual: mark timing positions, remove belt/gear, support cam/crank positions — this is advanced; use manual.

4. Disconnect coolant hoses and fittings
- Loosen hose clamps and remove hoses attached to pump. Plug hoses to prevent spillage.
- Remove any temperature sensor or bleed screws from pump area if present.

5. Unbolt and remove old pump
- Loosen water pump mounting bolts in a crisscross pattern to avoid warping. Use breaker bar for initial loosening.
- Remove all bolts and remove the pump assembly. Keep track of bolt lengths and positions.
- Inspect mating surface for corrosion; note any dowel pins or locating features.

6. Clean mating surfaces
- Scrape old gasket material with scraper, being careful not to gouge cast surfaces.
- Clean with solvent and a lint-free rag. Ensure bolt holes are clean.

7. Inspect and prepare replacement
- Inspect new pump: spin by hand to confirm smooth bearing, no play, intact seals.
- Compare new pump to old to confirm correct part and that inlet/outlet/hose positions match.
- Fit new gasket or O‑ring. If manual calls for sealant, apply thin even bead sparingly — do not overapply.

8. Install new pump
- Position pump onto engine, align dowels. Hand-start bolts to ensure threads line up.
- Tighten bolts in a crisscross/star pattern to seat the pump.
- Torque bolts to the workshop manual specification. If manual not available, torque to typical range for similar M8–M12 bolts (use manual when possible). Use threadlocker only if specified.

9. Reinstall pulley, fan, belts
- Reinstall water pump pulley; if tight on shaft, press gently or tap with soft mallet (do not damage seal).
- Tighten pulley bolts to spec.
- Reinstall fan or fan clutch, torque central nut to spec. Use a holding tool to prevent rotation.
- Refit drive belts, adjust tension to spec (use belt tension gauge or follow manual deflection). Replace belts if worn.

10. Reconnect hoses and sensors
- Reconnect coolant hoses and tighten new hose clamps. Reinstall any sensors or bleed valves.

11. Refill coolant and bleed air
- Close radiator drain, refill cooling system with Hino‑specified coolant/water mix.
- Bleed the system: open bleeder screws (if present) and run engine to operating temperature with radiator cap off to let air escape. Turn heater on full hot and cycle revs a few times. Top up fluid as air bleeds out.
- Check for leaks around pump, hoses, and pulley while running.

12. Final checks
- After Thermostat opens and coolant level stabilizes, reinstall radiator cap.
- Re-torque bolts after 10–50 km as required by manual.
- Check for leaks, proper belt alignment, and normal temperature rise under load.

How each tool is used (brief)
- Torque wrench: set to specified Nm; use for final tightening of pump bolts, pulley, and fan nut. Ensure clicking or digital readout is engaged.
- Breaker bar/impact: initial loosening of stubborn bolts; do not final-torque with impact.
- Pulley puller: attach jaws evenly to pulley, turn center bolt to extract pulley straight from shaft.
- Fan clutch wrench: hold fan hub while loosening/tightening large nut.
- Gasket scraper/razor: remove old gasket material carefully.
- Seal puller/pick: remove old O‑rings/seals without damaging bore.
- Belt tension gauge: check deflection/tension per manual.

Common pitfalls & how to avoid them
- Working on hot engine: always wait to avoid scalding.
- Not using correct parts: use OEM or approved aftermarket part; mismatched pump causes leakage or fitment issues.
- Not replacing gasket/seal: always replace gasket/O‑rings — never reuse.
- Over-tightening bolts: can warp pump housing or strip threads. Always torque to spec.
- Using impact for final torque: can give false torque; use torque wrench.
- Failing to bleed air: trapped air causes overheating. Use proper bleed procedure.
- Contaminated mating surfaces: leave them clean and dry before installing new gasket.
- Not replacing worn belts or clamps: leads to premature failure or leaks.
- Damaging bearings/seal on new pump: when installing pulley or fan, don’t press on impeller; press on hub only.
- Ignoring related components: if fan clutch, thermostat, hoses, or radiator show wear, replace while accessible.
- Disposal: don’t pour coolant down drain; collect and dispose per local regulations.

Replacement parts typically required
- Water pump assembly (OEM Hino 700 part for engine)
- Pump gasket and/or O‑ring(s)
- Drive belt(s) (recommended replacement)
- Hose clamps (recommended)
- Coolant (Hino-specified coolant)
- Optional: thermostat, fan clutch, hoses if aged
- Bolts/studs if corroded or torque-to-yield items specified by manual

Final checks after service
- Run engine to normal operating temperature; verify no leaks, correct temperature behavior, and belt tension.
- Road test under load and re-check for leaks and coolant level after cool-down.
- Record replacement date and part numbers.

Refer to the Hino 700 Series workshop manual for exact torque values, belt tensions, bleed points, and any engine‑specific removal of timing covers or accessories.
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