WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0]

id0112i1800700

Warning

•  Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.

•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.

•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Caution

•  Do not disassemble the water pump housing because it is a precision unit.

•  If engine coolant remaining in the engine flows out, the electrical components, wiring harnesses and connectors might get wet. Therefore, set aside the electrical components, wiring harnesses and connectors or protect them from getting wet.

•  Do not hold the pipe when removing/installing the water pump housing because the pipe may be damaged and the engine coolant may leak.

amxzzw00002967

•  If coolant leakage from the water pump is considered, refer to [Determination Criteria for Water Pump Coolant Leakage] to determine. (See Determination Criteria for Water Pump Coolant Leakage.)

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION.)

2.  Remove the air cleaner, air hose and resonance chamber No.1 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

4.  Remove the water pump drive belt with the generator drive belt still installed and set it aside. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

8.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

amxuuw00004241

1	Water pump pulley (See Water Pump Pulley Removal Note.) (See Water Pump Pulley Installation Note.)
2	Water pump housing (See Water Pump Housing Removal Note.) (See Water Pump Housing Installation Note.)
3	Gasket (See Gasket Installation Note.)
4	Water pump body (See Water Pump Body Removal Note.) (See Water Pump Body Installation Note.)
5	Gasket (See Gasket Installation Note.)

Water Pump Pulley Removal Note

Caution

•  Be careful not to damage the belt groove and surface of the water pump pulley when using tools, otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to the pulley, and rust.

1.  Align the water pump pulley hole with the water pump housing hole as shown in the figure.

amxzzw00002968

2.  Insert an appropriate bolt (length 70 mm {2.8 in}) into the water pump housing hole shown in the figure and lock the water pump pulley against rotation.

amxuuw00004243

3.  Loosen the water pump pulley bolts.

4.  Remove the bolt used for locking the water pump pulley against rotation.

5.  Remove the water pump pulley.

Water Pump Housing Removal Note

1.  Disconnect the ground.

amxuuw00004244

2.  Disconnect the heater hose.

amxzzw00002969

3.  Remove the front crossmember under cover. (See FRONT CROSSMEMBER UNDER COVER REMOVAL/INSTALLATION.)

4.  Place a container under the engine to collect the engine coolant remaining in the engine.

5.  Loosen the six water pump housing installation bolts and collect the draining engine coolant into a container.

Caution

•  Do not remove the water pump housing completely at this time because the engine coolant remaining in the engine will drain out.

6.  After the engine coolant stops draining, remove the water pump housing.

Water Pump Body Removal Note

1.  Remove the exhaust manifold insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

2.  Remove the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

3.  Remove the wiring harness clip using a flathead screwdriver.

amxzzw00002970

4.  Place a container under the engine to collect the engine coolant remaining in the engine.

5.  Loosen the three water pump body installation bolts and collect the draining engine coolant into a container.

Caution

•  Do not remove the water pump body completely at this time because the engine coolant remaining in the engine will drain out.

6.  After the engine coolant stops draining, remove the water pump body.

Gasket Installation Note

Caution

•  Do not apply oil (such as engine oil, ATF) to the gasket. Otherwise, it could cause a seal malfunction.

Water Pump Body Installation Note

1.  Remove sealant around the cylinder block screw holes before installing the water pump body.

2.  Tighten the water pump body installation bolts in the order shown in the figure.

ardjjw00005670

3.  Install the wiring harness clip.

amxuuw00004247

4.  Install the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

5.  Install the exhaust manifold insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

Water Pump Housing Installation Note

1.  Install the water pump housing using the following procedure:

(1)  Temporarily tighten the bolt shown in the figure.

amxuuw00004248

(2)  Tighten the bolts in the order shown in the figure.

ardjjw00005673

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

(3)  Tighten the bolt shown in the figure.

amxuuw00004249

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

2.  Connect the heater hose.

amxzzw00002969

3.  Connect the ground.

amxuuw00004244

4.  Install the front crossmember under cover. (See FRONT CROSSMEMBER UNDER COVER REMOVAL/INSTALLATION.)

Water Pump Pulley Installation Note

Caution

•  Be careful not to damage the belt groove and surface of the water pump pulley when using tools, otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to the pulley, and rust.

1.  Install the water pump pulley to the water pump housing and temporarily tighten the bolts.

2.  Align the water pump pulley hole with the water pump housing hole as shown in the figure.

amxzzw00002968

3.  Insert an appropriate bolt (length 70 mm {2.8 in}) into the water pump housing hole shown in the figure and lock the water pump pulley against rotation.

amxuuw00004243

4.  Completely tighten the water pump pulley bolts to the specified torque.

5.  Remove the bolt used for locking the water pump pulley against rotation.

Determination Criteria for Water Pump Coolant Leakage

•  If any coolant residue (green) around the steam hole can be verified but there is no large solid matter adhered to it as shown in the following figure, the residue is caused by a small amount of steam blowing through the steam hole, not coolant leakage. Therefore, this does not indicate a problem.

ac3ccw00000026

•  If a large amount of solid matter is adhered to the area around the steam hole or the area is wet by coolant as shown in the following figure, a water pump seal or gasket malfunction can be considered. Therefore, perform the coolant leakage inspection and replace the water pump or gasket. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

ac3ccw00000027