Water Pump: Service and Repair

REMOVAL PROCEDURE
1. Remove the radiator cap.





2. Open the drain plug (3). Drain the coolant into a container.
3. Close the drain plug (3).
4. Remove the two bolts securing the A/C flexible hose to the radiator (if equipped). Reposition the hose to the rear.





5. Remove the four bolts that secure the shroud (1) to the radiator (4).





6. Remove the four fan clutch mounting bolts.
7. Remove the shroud, the fan clutch (4), and the cooling fan (3) together.
8. Remove the coolant pump pulley (1) from the coolant pump shaft. Disengage the generator/coolant pump drive belt (2) as the pulley is removed.





IMPORTANT: It is not necessary to remove the crankshaft pulley center bolt when removing the crankshaft pulley (3).

9. Remove the five bolts and the crankshaft pulley (3) from the crankshaft.
10. Remove the timing belt.
11. Loosen the A/C compressor drive belt (if equipped).
12. Remove one bolt and the engine oil level indicator tube, with the O-ring, from the oil pump.
13. Remove the generator mounting bolt and bracket at the coolant pump.
14. Remove the timing belt tensioner (5) and pulley (3).





15. Remove the five coolant pump mounting bolts and the coolant pump (1) with the gasket (2) and rubber seals from the engine.
16. Clean the gasket material, corrosion and debris from the mating surfaces on the coolant pump (1) and the engine block.

INSTALLATION PROCEDURE

NOTICE: Refer to Fastener Notice in Service Precautions.





1. Install the coolant pump (1) with a new gasket (2) to the engine. Secure the pump with five bolts.
^ Tighten the coolant pump bolts to 12 Nm (106 inch lbs.).

2. Install the rubber seals between the coolant pump and the oil pump.
3. Install the rubber seals between the coolant pump and the cylinder head.
4. Connect the engine oil level indicator tube to the engine. Secure the engine oil level indicator tube with a mounting bolt. Do not tighten fully.
^ Tighten the engine oil level indicator tube mounting bolt to 11 Nm (97 inch lbs.).

5. Install the timing belt tensioner and pulley.
6. Install the timing belt.





7. Install the crankshaft pulley (3). Secure the crankshaft pulley with five bolts.
^ Tighten the crankshaft pulley bolts to 16 Nm (12 ft. lbs.).





8. Position the generator/coolant pump drive belt (2) on the pulley (1) before installing the coolant pump pulley (1).
9. Install the coolant pump pulley (1) to the coolant pump shaft.

IMPORTANT: The fan clutch, cooling fan and radiator shroud must be installed together because of insufficient clearance to install these parts in separate steps.

10. Install the fan clutch, cooling fan and shroud together.
11. Secure the fan clutch (4), cooling fan (3) and shroud with the four fan clutch nuts and the four shroud bolts.
^ Tighten the fan clutch nuts to 11 Nm (97 inch lbs.).
^ Tighten the shroud bolts to 11 Nm (97 inch lbs.).





12. Adjust the air conditioner compressor drive belt (if equipped).





13. Adjust the generator/coolant pump drive belt tension (1) so that the belt deflects 5 to 8 mm (0.02 to 0.32 in) under 10 kg (22 lbs.) of applied pressure.
^ Tighten the generator upper mounting bolt to 27 Nm (20 ft. lbs.) while holding the generator/coolant pump drive belt tension.

14. Fill the radiator will an approved coolant.
15. Install the radiator cap to the radiator.
16. Reposition the A/C flexible hose to the radiator. Secure with the two bolts.
^ Tighten the air conditioning flexible hose bolts to 15 Nm (11 ft. lbs.).