Alphabetical Index

Engine & Engine Overhaul
ENGINE MECHANICAL

Water Pump


REMOVAL & INSTALLATION
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.


1.2L Engine


See Figure 1
Fig. 1: Water pump assembly-1.2L engine
  1. Disconnect the negative battery cable.
  2. Drain the coolant and engine oil into a suitable containers.
  3. Remove the dipstick and tube.
  4. Remove the alternator. Refer to the procedure in Section 2.
  5. Remove the crankshaft pulley.
  6. Remove the timing belt cover.
  7. Remove the timing belt, tensioner and camshaft sprocket, as described later in this section.
  8. Remove the rear timing belt cover.
  9. Raise and safely support the vehicle on jackstands.
  10. Remove the flywheel housing cover.
  11. Remove the oil pan, oil pan plate and oil strainer.
  12. Remove the air suction manifold bracket from the air manifold and crankcase cover.
  13. Remove the water pump cover retainer bolts from the crankcase cover. Lift the water pump cover off and clean all gasket material from both mating surfaces.
  14. Remove the water pump impeller bolt and impeller, as well as the seal.

To install:

  1. Install a new water pump seal using seal installer 499795400 or equivalent. Install the water pump impeller and bolt. Tighten the bolt to 7-9 ft. lbs. (9-12 Nm).
  2. Install the water pump cover to the crankcase cover. Tighten the retainer bolts to 8-12 ft. lbs. (10-16 Nm)).
  3. Install the air suction manifold bracket from the air suction manifold to the crankcase cover.
  4. Install the oil strainer, oil pan plate and oil pan. Refer to the procedure in this section.
  5. Install the flywheel housing cover.
  6. Lower the vehicle.
  7. Install the rear timing belt cover.
  8. Install the camshaft sprocket, tensioner and timing belt. Refer to the procedures in this section.
  9. Install the timing belt cover.
  10. Install the crankshaft pulley.
  11. Install the alternator.
  12. Install the dipstick and tube.
  13. Refill the crankcase with clean oil.
  14. Refill the cooling system.
  15. Connect the negative battery cable.
  16. Start the vehicle and check for leaks.

1.6L, 1.8L and 2.7L Engines


See Figure 2
Fig. 2: Water pump assembly-1.6L, 1.8L and 2.7L engines

  1. Drain the coolant into a suitable container.
  2. Disconnect the radiator outlet hose and water bypass hose from the water pump.
  3. Loosen the pulley nuts. Loosen the alternator assembly and remove the drive belt.
  4. Remove the front belt cover.
  5. Unfasten the water pump mounting bolts and remove the water pump.

To install:

  1. Clean the gasket material from both mating surfaces. Always use new gaskets during installation.
  2. Install the water pump and pump mounting bolts. Tighten the mounting bolts to 7-8 ft. lbs. (9-10 Nm).
  3. Install the front belt cover.
  4. Install the alternator drive belt and drive belt cover. Adjust the drive belt to the proper tension. Tighten the water pump pulley bolts to 7-8 ft. lbs. (9-10 Nm).
  5. Inspect the coolant hoses and replace as necessary. Install the radiator outlet hose and water bypass hose on the water pump.
  6. Fill the radiator with coolant. Start the engine and allow it to reach operating temperature. Check for leaks.


2.2L, 2.5L and 3.3L Engines


See Figures 3, 4, 5, 6, 7, 8 and 9

Fig. 3: Water pump assembly-2.2L, 2.5L and 3.3L engines

Fig. 4: Water pump bolt tightening sequence-2.2L and 2.5L engines

Fig. 5: Water pump bolt tightening sequence-3.3 engine

Fig. 6: After loosening the hose clamps, detach the water pump's hoses-2.2L engine shown

Fig. 7: Remove the water pump retainer bolts

Fig. 8: Remove the water pump from the engine

Fig. 9: Remove the water pump gasket
  1. Disconnect the negative battery cable.
  2. Drain the coolant into a suitable container.
  3. Disconnect the radiator outlet hose.
  4. Remove the radiator fan motor assembly.
  5. Remove the accessory drive belts.
  6. Remove the timing belt, tensioner and camshaft angle sensor. Refer to the procedure in this section for removal and installation steps.
  7. Remove the left side camshaft pulley(s) and left side rear timing belt cover. Remove the tensioner bracket.
  8. Disconnect the radiator hose and heater hose from the water pump.
  9. Remove the water pump retainer bolts.
  10. Remove the water pump.

To install:

  1. Clean the gasket mating surfaces thoroughly. Always use new gaskets during installation.
  2. Install the water pump and tighten the bolts, in sequence, to 7-10 ft. lbs. (10-14 Nm). After tightening the bolts once, retighten to the same specification again.
  3. Inspect the radiator hoses for deterioration and replace as necessary. Connect the radiator hose and heater hose to the water pump.
  4. Install the left side rear timing belt cover, left side camshaft pulley(s) and tensioner bracket.
  5. Install the camshaft angle sensor, tensioner and timing belt.
  6. Install the accessory drive belts.
  7. Install the radiator ran motor assembly.
  8. Install the radiator outlet hose.
  9. Fill the system with coolant.
  10. Connect the negative battery cable.
  11. Start the engine and allow it to reach operating temperature.
  12. Check for leaks.



END OF SECTION