Water Pump: Service and Repair

REMOVAL
1. Radiator cap.
2. Open drain plug and drain coolant into appropriate container.
3. Close drain plug.
4. Two bolts securing A/C flexible hose to radiator (if equipped); reposition to the rear.
5. Four bolts securing shroud to radiator and four fan clutch mounting nuts.
6. Shroud, fan clutch and cooling fan together.
7. Coolant pump pulley from coolant pump shaft, disengaging generator/coolant pump drive belt as pulley is removed.
8. Five bolts and crankshaft pulley from crankshaft.

NOTE: It is not necessary to remove the crankshaft pulley center bolt when removing the crankshaft pulley.

9. Timing belt.
10. Loosen A/C compressor drive belt (if equipped).
11. One bolt and engine oil level indicator tube, with O-ring, from oil pump.
12. Generator mounting bolt and bracket at coolant pump.
13. Timing belt tensioner and pulley.
14. Five coolant pump mounting bolts and coolant pump with gasket and rubber seals from engine.
^ Clean the mating surfaces on coolant pump and engine block of gasket material, corrosion and debris.

INSTALLATION
1. Coolant pump with new gasket to engine; secure with five bolts.
^ Tighten the coolant pump bolts to 12 Nm (106 inch lbs.).
2. Rubber seals between coolant pump and oil pump and between coolant pump and cylinder head.
3. Engine oil level indicator tube to engine; secure with mounting bolt. Do not tighten fully.
4. Generator mounting bracket to coolant pump; secure with mounting bolt. Do not tighten fully.
^ Tighten the engine oil level indicator tube mounting bolt to 11 Nm (97 inch lbs.).
5. Timing belt tensioner and pulley.
6. Timing belt.
7. Crankshaft pulley; secure with five bolts.
^ Tighten the crankshaft pulley bolts to 16 Nm (12 ft. lbs.).
8. Position generator/coolant pump drive belt on pulley before installing coolant pump pulley.
9. Coolant pump pulley to coolant pump shaft.

NOTE: Fan clutch, cooling fan and radiator shroud must be installed together because of insufficient clearance to install in separate steps.

10. Fan clutch, cooling fan and shroud; secure with four fan clutch nuts and four shroud bolts.

^ Tighten
- Fan clutch nuts to 11 Nm (97 inch lbs.).
- Shroud bolts to 11 Nm (97 inch lbs.).
^ Adjust
- Air conditioner compressor drive belt (if equipped).
- Generator/coolant pump drive belt tension so the belt deflects 5 to 8 mm (0.20 to 0.32-inch) under 10 kg (22 lbs.) of applied pressure.
^ Tighten the generator upper mounting bolt to 27 Nm (20 ft. lbs.) while holding generator/coolant pump drive belt tension.
11. Fill radiator with approved coolant.
12. Radiator cap to radiator.
13. Reposition A/C flexible hose to radiator (if equipped); secure with two bolts.
^ Tighten the air conditioning flexible hose bolts to 15 Nm (11 ft. lbs.).