Water Pump: Service and Repair

Water Pump Replacement (L4)

Special Tools

EN-43651 - Water Pump Holding Tool

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

3. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LAF) Exhaust Manifold Heat Shield Replacement (LAF).

4. If equipped, remove the coolant heater.

5. Remove the catalytic converter. Refer to Catalytic Converter Replacement (L4) Service and RepairCatalytic Converter Replacement (LDK or LHU) .

6. Remove the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LEA or LUK) Engine Coolant Thermostat Housing Replacement (LEA or LUK)Engine Coolant Thermostat Housing Replacement (LHU) Engine Coolant Thermostat Housing Replacement (LHU).





7. Remove the water pump cover (2), fasteners (3) and gasket (1) from the engine front cover.





Note:
A drain plug has been provided at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.

8. Drain the coolant from the water pump using the plug at the bottom of the pump. Install the plug when finished.





Note:
The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed.

9. Align the EN-43651 - water pump holding tool(1) with the threads on the water pump sprocket. Tighten the water pump holding tool fasteners (2).





10. Secure the water pump holding tool with the previously removed water pump cover fasteners (1) into the engine front cover.





11. Remove the water pump sprocket to water pump fasteners (1).





Note:
Be sure to remove both water pump bolts from the front of the engine block.

12. Remove the front water pump fasteners (1).





13. Remove the rear water pump fasteners (1).





14. Remove the water pump (1).





15. If replacing the water pump cover remove the water pump rear cover fasteners (4).

16. Separate the water pump cover (1) from the water pump (3).

17. Remove and discard the water pump O-ring seal (2).

Installation Procedure





Caution:
Refer to Fastener Caution Fastener Caution.

1. If replacing the water pump cover (1), install a new O-ring (2) to the water pump (3) and tighten the fasteners (4) to 25 Nm (18 lb ft).





Note:
A guide pin can be created to aid in water pump alignment. Use a M 6 m x 6 mm x 50.8 mm stud (2 in). Thread the pin into the water pump sprocket.

2. Using a guide pin (2), align the pin with the water pump holding tool.

3. Position the water pump (1) against the engine block and hand tighten the water pump fasteners (3).





4. Install 2 water pump sprocket to water pump fasteners (1). After the fasteners are snug, remove the guide pin (2) and install the 3rd fastener (3) and tighten to 10 Nm (89 lb in).





5. Install the water pump fasteners (1) at the front of the engine. Hand tighten at this time.

6. Tighten the water pump fasteners at the front and rear of the water pump to 25 Nm (18 lb ft).





7. Remove the water pump cover fasteners (1) from the engine front cover and water pump holding tool.





8. Remove the EN-43651 - water pump holding tool(1) from the water pump sprocket.





9. Install the water pump access plate (2) gasket (1) and fasteners (3) and tighten to 10 Nm (89 lb in).

10. If equipped, Install the coolant heater.

11. Install the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LEA or LUK) Engine Coolant Thermostat Housing Replacement (LEA or LUK)Engine Coolant Thermostat Housing Replacement (LHU) Engine Coolant Thermostat Housing Replacement (LHU).

12. Install the catalytic converter. Refer to Catalytic Converter Replacement (L4) Service and RepairCatalytic Converter Replacement (LDK or LHU) .

13. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LAF) Exhaust Manifold Heat Shield Replacement (LAF).

14. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

16. Refill the coolant system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).