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PSI240SX · 10-14-2007, 05:06 PM

Water Pump Replacement.

REMOVAL

Drain coolant from drain plugs on radiator and both sides of cylinder block.

Remove water pump drain plug.

Remove right side engine mounting, mounting bracket and nuts.

Remove drive belts and idler pulley bracket.

Remove chain tensioner cover and water pump cover

While pushing timing chain tensioner sleeve, apply a stopper pin so it does not return.

Then remove the chain tensioner assembly.

Remove the 3 water pump fixing bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley 20°backwards.

Fasten two M8 bolts to two M8 threaded holes (out of 3) water pump fixing bolt holes
Tighten M8 bolts by turning half turn alternately until they reach timing chain rear case.

In order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time.
Lift up water pump and remove it.
CAUTION:
When lifting up on the water pump, do not allow the water pump gear to hit timing chain.

When removing the water pump assembly, be careful not to get coolant on drive belt.
NOTE: The water pump cannot be disassembled and should be replaced as a unit.

INSTALLATION:
Apply engine oil and coolant to the O-rings.

Before installing water pump, remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper. Also, remove traces of liquid gasket from mating surface of front cover.

NOTE: Do not allow cylinder block to nip O-rings when installing water pump.

Apply a continuous bead of liquid gasket to mating surface of chain tensioner cover and water pump cover.

Return the crankshaft pulley to its original position by turning it 20°forward.

Install timing chain tensioner, then remove the stopper pin.
NOTE: After installing the tensioner, race the engine at about 3,000 RPM under no-load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

Install drain plug on cylinder block.
Reinstall any parts removed in reverse order of removal.
NOTE: After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.

10-14-2007, 05:06 PM	#59
PSI240SX Member Join Date: May 2006 iTrader: (2) Posts: 34	Water Pump Replacement. REMOVAL Drain coolant from drain plugs on radiator and both sides of cylinder block. Remove water pump drain plug. Remove right side engine mounting, mounting bracket and nuts. Remove drive belts and idler pulley bracket. Remove chain tensioner cover and water pump cover While pushing timing chain tensioner sleeve, apply a stopper pin so it does not return. Then remove the chain tensioner assembly. Remove the 3 water pump fixing bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley 20°backwards. Fasten two M8 bolts to two M8 threaded holes (out of 3) water pump fixing bolt holes Tighten M8 bolts by turning half turn alternately until they reach timing chain rear case. In order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time. Lift up water pump and remove it. CAUTION: When lifting up on the water pump, do not allow the water pump gear to hit timing chain. When removing the water pump assembly, be careful not to get coolant on drive belt. NOTE: The water pump cannot be disassembled and should be replaced as a unit. INSTALLATION: Apply engine oil and coolant to the O-rings. Before installing water pump, remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper. Also, remove traces of liquid gasket from mating surface of front cover. NOTE: Do not allow cylinder block to nip O-rings when installing water pump. Apply a continuous bead of liquid gasket to mating surface of chain tensioner cover and water pump cover. Return the crankshaft pulley to its original position by turning it 20°forward. Install timing chain tensioner, then remove the stopper pin. NOTE: After installing the tensioner, race the engine at about 3,000 RPM under no-load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern. Install drain plug on cylinder block. Reinstall any parts removed in reverse order of removal. NOTE: After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.