Water Pump: Service and Repair

Water Pump Assembly:

REMOVAL

1. Drain engine oil and coolant.
2. Remove oil dip stick, guide tube and guide tube seal.
3. Remove V-belt and alternator.
4. Remove crankshaft pulley. To prevent crankshaft from turning, use crank and camshaft pulley wrench (tool #499205500) and puller (tool #899521421) or aftermarket equivalents.
5. Remove outer cam belt cover.

NOTE: The timing belts will need to be removed. Refer to TIMING BELT.

6. Remove cam belt tensioner spring and tensioner.
7. Remove cam drive plate from end of crankshaft and remove belt.

NOTE: Before removal, mark belt with direction of rotation to facilitate correct reinstallation.

8. Remove camshaft drive pulley from crankshaft.
9. Remove camshaft driven pulley. To prevent camshaft from turning, remove pulley with crank and camshaft pulley wrench (tool #499205500) or aftermarket equivalent.
10. Remove inner cam belt cover and cover mount.
11. Remove flywheel housing.
12. Remove oil pan and gasket.

DISASSEMBLY

1. Remove water pump cover. Lock balancer shaft with a screwdriver to prevent turning, unscrew impeller retaining bolt and remove impeller.
2. Remove crankcase cover.

Mechanical Seal Removal:

3. Press out mechanical seal with mechanical seal press (tool #498835400) or aftermarket equivalent. The seal can also be removed with mechanical seal remover (tool #499715400) and mechanical seal remover plate (tool #499685510).

INSPECTION

1. Check ceramic seat for cracks.
2. Check contact surface between mechanical seal and ceramic seat for wear or damage.
3. Check impeller for corrosion or damage.
4. Check oil seal lip for wear, damage or hardening.
5. Check all related parts for wear, cracks or other damage. Replace any components not in serviceable condition.

ASSEMBLY

Mechanical Seal Installation:

1. Using mechanical seal press (tool #498835400) or mechanical seal installer (tool #499795400) or aftermarket equivalents, press mechanical seal into crankcase cover. Be sure to seat seal against cover surface.
a. Prior to pressing, coat outer circumference of mechanical seal with "Three bond No. 1303" or equivalent. Coat impeller sliding surface with coolant.
b. When replacing pump impeller, install a new mechanical seal.
2. Install crankcase cover. Always use a new gasket.
3. Manually press impeller onto balancer shaft and measure clearance between impeller blade tips and crankcase cover. Standard clearance is 0.012 - 0.035 in (0.3 - 0.9 mm). Maximum clearance is 0.043 in (1.1 mm). Add or subtract spacers as needed to obtain correct clearance.

Water Pump Impeller Installation:

4. Install impeller retaining bolt and washer. Torque to 6.9 - 7.6 ftlb (9.3 - 10.3 Nm). Lock balancer shaft with a screwdriver while tightening impeller bolt.
5. Install pump cover with a new gasket.
6. Install remaining components in reverse order of removal.
7. Fill cooling system with approved coolant. Add correct quantity of oil to crankcase.
8. Warm engine to operating temperature. Check that coolant is circulating and system is full. Ensure that there are no leaks.