WATER PUMP REMOVAL/INSTALLATION [MZR-CD 2.2]

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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.

Note

•  Replace the water pump after removing the water pump and thermostat case as a single unit from the engine.

1.  Disconnect the negative battery cable.

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

5.  Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

6.  Loosen the water pump pulley bolts before removing the drive belt.

7.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.  Remove the boost sensor. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Remove the thermostat and thermostat cover. (See THERMOSTAT REMOVAL/INSTALLATION [MZR-CD 2.2].)

11.  Disconnect the oil pressure switch connector and A/C compressor connector.

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

15.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD 2.2].)

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1	Water outlet and upper radiator hose component (See Water Outlet Installation Note.)
2	Water hose
3	Wiring harness bracket
4	Water pump and thermostat case component (See Water Pump And Thermostat Case Component Removal Note.) (See Water Pump And Thermostat Case Component Installation Note.)
5	Water pump (See Water Pump Installation Note.)
6	Thermostat case
7	O-ring (See O-ring Installation Note.)

Water Pump And Thermostat Case Component Removal Note

1.  Remove the four thermostat case installation bolts.

2.  Move the water pump and the thermostat case component inside the engine compartment and remove the water pump pulley.

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3.  Remove the water pump and the thermostat case component.

O-ring Installation Note

1.  Apply engine coolant to a new O-ring.

2.  Install the O-ring.

Water Pump Installation Note

1.  Tighten the water pump installation bolts in the order shown in the figure.

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Water Pump And Thermostat Case Component Installation Note

1.  Place the water pump and the thermostat case component in the engine compartment.

2.  Put the water pump and the thermostat case component in the engine compartment in the position shown in the figure.

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3.  Align rotation lock holes A and B on the water pump pulley and on the water pump pulley hub, and temporarily tighten the four water pump pulley bolts.

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Caution

•  Verify that the thermostat case O-ring has not fallen off before installing the thermostat case.

4.  Install the thermostat case to the cylinder block and temporarily install the four bolts.

5.  Tighten the thermostat case installation bolts in the order shown in the figure.

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6.  Insert a suitable hexagonal bit socket into the rotation lock hole A or B and lock the water pump pulley against rotation.

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7.  Tighten the water pump pulley bolts to the specified tightening torque.

Water Outlet Installation Note

1.  Tighten the water outlet installation nuts and bolt in the order shown in the figure.

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