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drain coolant until below water pump level. loosen water pump pulley bolts.then remove drive belt by rotating belt tensioner.remove drive belt from the right of idler pulley.carefully release the drive belt tensioner spring tension.then remove water pump pulley bolts and pulley.remove water pump bolts and water pump pay attention to the position old water pump when removing water pump so you can line up new water pump holes to the engine. be sure clean engine water pump mounting surface use gasket remover dont scratch engine surface when cleaning removing old gasket material. take new water pump gasket get it mounting holes line up with new water pump mounting holes.when done getting engine water pump surface clean.water pump gasket paper you need to put thin layer of sealer on both sides of water pump gasket use RTV SILICONE.LET SET UP 10 MINUTES. PUT GASKET ON WATER PUMP BUT FIRST MAKE SURE LINE UP GASKET HOLES WITH WATER PUMP HOLES BEFORE PUTTING ON THE GASKET SEALER.when gasket sealer set up 10 minutes then install new water pump with gasket to the engine torque to 89 inch lbs.or 10 NM that is about 7 ft lbs torque.you should be able turn water pump by hand if you cant turn water pump by hand got too tight damage water pump shaft bearing.when all done wait for THREE HOURS. before adding coolant i let RTV CURE SOME. torque water pump pulley bolts 18 ft lbs.
Drain cooling system.
Remove timing belt. Refer to Engine for procedure.
Remove water pump mounting bolts.
Separate pump from water inlet pipe and remove water pump.
Timing Belt Removal
Raise vehicle and remove accessory drive belt splash shield (Fig. 66).
Remove accessory drive belts.
Remove crankshaft pulley and damper (Fig. 68).
Support engine and remove right side engine mount.
Remove engine support bracket (Fig. 67).
Remove timing belt covers (Fig. 67).
Mark belt running direction for installation (Fig. 69).
Loosen timing belt tensioner bolt (Fig. 71) and remove timing belt.
Remove crankshaft sprocket flange shield (Fig. 68). CAMSHAFT SPROCKETS To remove camshaft sprockets
Hold camshaft sprocket with Spanner Tool MB-990775. Loosen and remove bolt and washer (Fig. 70).
Remove camshaft sprocket from camshaft. To install camshaft sprockets:
Place camshaft sprocket on camshaft.
Install bolt and washer to camshaft. Using Spanner Tool MB-990775, hold
camshaft sprocket and torque bolt to 95 Nm (70 ft. lbs.) (Fig. 70).
TIMING BELT TENSIONER
Install timing belt tensioner and tensioner spring.
Hook spring upper end to water pump pin and lower end to tensioner bracket with hook out (Fig. 71).
Turn timing belt tensioner counterclockwise full travel in adjustment
slot and tighten bolt to temporarily hold this position (Fig. 72).
Install timing belt on crankshaft sprocket and keep belt tight on
tension side (Fig. 69). Install belt on the front (radiator side)
camshaft sprocket. Install belt on the water pump pulley, rear camshaft
sprocket and finally on the timing belt tensioner.
Rotate the front camshaft sprocket in opposite direction to take up belt
slack. Check that all timing marks are aligned (Fig. 69).
Install crankshaft sprocket flange (Fig. 68).
Loosen tensioner bolt and allow spring to tension timing belt.
Turn crankshaft two full turns in clockwise direction. Turn smoothly and in clockwise direction ONLY.
Align the timing marks on the sprockets and tighten the timing belt tensioner locking bolt to 28 Nm (250 in. lbs.) torque.
Install timing belt covers.
Install engine support bracket.
Install right side engine mount.
Install crankshaft damper and pulleys (Fig. 68). Tighten damper center bolt to 135 Nm (100 ft. lbs.) .
Install accessory drive belts.
Install accessory drive belt splash shield (Fig. 66).
Be sure to also replace all the cam and crank seals why you are there. Might as well put a belt on too.
FOR THE 3.3 OR 3.8 MOTORS.
Drain Cooling System.
Remove accessory drive belt.
Remove right front lower fender shield.
Remove water pump pulley bolts and remove pulley.
Remove water pump mounting screws. Remove water pump.
Remove and discard O-ring seal.
Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface
Install new O-ring into groove.
Install water pump to chain case cover. Tighten screws to 12 Nm (105 inch lbs.) .
Rotate pump by hand to check for freedom of movement.
Position pulley on pump. Install screws and tighten to 30 Nm (250 inch lbs.) .
Install accessory drive belt.
Install right front lower fender shield.
Refill Cooling System.
FOR THE 2.4 MOTOR
Disconnect negative cable from battery.
Raise vehicle on a hoist. Remove right inner splash shield.
Remove accessory drive belts.
Drain cooling system.
Support engine from the bottom and remove right engine mount.
Remove right engine mount bracket.
Remove timing belt. Refer to Engine for procedure.
Remove timing belt idler pulley.
Hold camshaft sprocket with Special tool C-4687 and adaptor C-4687-1 while removing bolt. Remove both cam sprockets.
Remove rear timing belt cover.
Install new O-ring gasket in water pump body O-ring groove. CAUTION:
Make sure O-ring is properly seated in water pump groove before
tightening screws. An improperly located O-ring may cause damage to the
O-ring and cause a coolant leak.
Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs.) .
Pressurize cooling system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.
Rotate pump by hand to check for freedom of movement.
Install rear timing belt cover.
Install camshaft sprockets and torque bolts to 101 Nm (75 ft. lbs.) .
Install timing belt idler pulley and torque mounting bolt to 61 Nm (45 ft. lbs.) .
Install timing belt. Refer to Engine for procedure.
Install right engine mount bracket and engine mount. Refer to Engine for procedure.
Fill cooling system.
Install accessory drive belts.
Lower vehicle and connect battery cable.
Place a large drain pan under the radiator drain plug. Drain and properly contain the engine coolant.
This procedure requires removing the engine timing belt and the auto tensioner. To help assure proper alignment at assembly, it may be helpful to set the engine at TDC on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.
Remove the accessory drive belts and crankshaft damper.
Remove the right engine mount. This requires safely supporting the engine with a floor jack and wood block so the mount can be removed.
Remove the timing belt covers.
Remove the timing belt and tensioner.
Fig. Fig. 3: Remove the water pump mounting bolts
Fig. Fig. 4: Pull the water pump assembly off of the engine and inlet pipe
Fig. Fig. 5: Open the water pump housing and examine for cracks or damage
Fig. Fig. 6: Replace the water pump housing gasket using a scraper tool
Fig. Fig. 7: Always keep the water pump's mounting bolts lined up with their correct mounting holes
Remove the water pump mounting bolts.
Separate the water pump from the water inlet pipe and remove the pump.
Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent, and excessive looseness or rough turning bearings. Any problems require a new pump.
Install a new O-ring on the water inlet pipe. Wet the O-ring with water to make installation easier. DO NOT use oil or grease on the O-ring.
Install a new gasket on the water pump and fit the pump inlet opening over the water pipe. Press the assembly together to force the pipe into the water pump.
Install the water pump-to-engine bolts and tighten to 20 ft. lbs. (27 Nm).
Install the timing belt and timing belt tensioner. Set the timing belt tension.
Install the timing belt covers. Install the right engine mount. Remove the floor jack and engine block from underneath the engine.
Install the crankshaft damper.
Install the accessory drive belts and set to the proper tension.
Connect the negative battery cable.
Fill and bleed the engine cooling system.
Start the engine and verify proper operation, with no leaks
TIMING BELT & SPROCKETS R & I NOTE: Some procedures may differ slightly due to engine construction. Removal 1) Remove all necessary air ducts. Position No. 4 piston at TDC of compression stroke. Align timing marks. See Fig. 2. Remove fan and fan shroud. Remove belts. If necessary, remove radiator and splashguard. 2) Prevent engine from rotating and remove crankshaft timing pulley retaining bolt. Remove upper and lower timing belt covers. Remove spring from tension pulley. Loosen adjusting bolt and move pulley toward water pump. Remove timing belt. CAUTION: Ensure pistons are at TDC when rotating camshaft or damage may result. Inspection 1) Handle timing belt carefully. Avoid twisting or kinking belt. Do not allow belt to become contaminated by water, oil, dirt or other contaminates. Inspect belt for cracks or damage. If necessary, replace. 2) Measure tension pulley spring length and force. Spring length should not exceed 2.76" (70.2 mm) and spring force should not be less than 197-347 lbs. (27-48 kg). 3) Replace tension pulley spring if not within specification. Installation 1) Pull tensioner fully toward water pump side and temporarily tighten retaining bolt. Ensure No. 4 cylinder is at TDC on compression stroke by rotating crankshaft until keyway aligns with mark on front crankshaft seal housing (12 o'clock). Rotate camshaft until timing mark on cam gear (arrow) aligns with mark on upper camshaft cover (notch). See Fig. 2. NOTE: When timing marks are aligned as stated above, No. 4 piston is at TDC on compression stroke. 2) Position timing belt over crankshaft sprocket, oil pump sprocket, camshaft sprocket and tensioner in that order. Ensure belt is positioned in sequence given and without slack between sprockets. Loosen tension sprocket adjusting bolt allowing spring tension to tighten belt. Tighten adjusting bolt temporarily. 3) Temporarily install crankshaft pulley bolt and rotate crankshaft 2 complete revolutions in opposite direction of engine rotation, until marks on crankshaft and front oil seal retainer are aligned again. See Fig. 2. Loosen tensioner lock bolt, allowing tesioner spring to fully adjust tension. Tighten tensioner lock bolt. 4) Install timing belt covers. To complete installation, reverse removal procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS table at end of this article. Fig. 2: 2.3L & 2.6L Timing Alignment Marks Courtesy of Isuzu Motor Co
Disconnect the negative battery cable. Drain the cooling system.
Remove the distributor cap and rotor. Remove the rotor adapter, the dust shield and the distributor housing.
Remove the fan. The fan must be held stationary with tool 11 5 030 or some sort of flat blade cut to fit over the hub and drilled to fit over 2 of the studs on the front of the pulley. Remove the fan coupling nut; left hand thread-turn clockwise to remove.
Remove the belt and pulley.
Remove the rubber guard and distributor and or upper timing belt cover.
Compress the timing tensioner spring and clamp pin with the proper tool.
Observe the installed position of the tensioner spring pin on the water pump housing for reinstallation purposes.
Remove the water hoses, remove the 3 water pump bolts and remove the pump.
Clean the gasket surfaces and use a new gasket.
Install the water pump in position. Note the position of the tensioner spring pin. Torque M8 bolts to 16-17 ft. lbs. (20-24 Nm) and M6 bolts to 6-7 ft. lbs. (8-10 Nm). Connect the hoses.
Release the tensioner from the holding pin. Install the upper timing cover. Install the pulley and tighten the bolts to 6-7 ft. lbs. (8-10 Nm). Install the belt and tighten.
Install the fan, distributor housing and dust shield. Tighten the rotor adapter to 39-47 ft. lbs. (55-65 Nm). Install the rotor, O-ring and cap.
Loosen and remove the engine accessory drive belts.
Remove the cooling fan assembly and the water pump pulley.
Drain the fluid from the power steering reservoir.
Unbolt and remove the power steering pump. Unbolt the hydraulic line brackets from the upper timing cover and move the pump out of the work area without disconnecting the hydraulic lines.
Disconnect and remove the starter motor if a flywheel holder (part No. J–38674) is to be used.
Remove the upper timing belt cover.
Rotate the crankshaft to set the engine at TDC/compression for the No. 1 cylinder. The arrow mark on camshaft sprocket aligns with mark on the rear timing cover.
Remove the crankshaft pulley.
Remove the lower timing belt cover.
Verify that the engine is set at TDC/compression for the No. 1 cylinder. The notch on the crankshaft sprocket aligns with the pointer on the oil seal retainer.
Release and remove the tensioner spring to release the timing belt's tension.
Remove the timing belt.
Unbolt the tensioner pulley bracket from the engine's front cover.
If necessary, unbolt and remove the camshaft sprockets. Use a puller to remove the crankshaft pulley if necessary. Don't loose the crankshaft sprocket key.
Install the camshaft and crankshaft sprockets if they were removed. Align the timing marks and be sure to install any keys. Tighten the camshaft sprocket bolt to 43 ft. lbs. (59 Nm).
Install the tensioner assembly. Tighten the tensioner mounting bolt to 14 ft. lbs. (19 Nm). Tighten the cap bolt to 9 ft. lbs. (13 Nm).
Make sure the crankshaft and the camshaft sprockets are aligned with their timing marks. Install the timing belt onto the sprockets using the following sequence: first, crankshaft sprocket; second, oil pump sprocket; third, camshaft sprocket.
Loosen the tensioner mounting bolt. This will allow the tensioner spring to apply pressure to the timing belt.
After the spring has pulled the timing belt as far as possible, temporarily tighten the tensioner mounting bolt to 14 ft. lbs. (19 Nm).
NOTE: Remove the flywheel holder before rotating the crankshaft. Reinstall the holder to torque the crankshaft pulley bolt.
Rotate the crankshaft counterclockwise two complete revolutions to check the rotation of the belt and the alignment of the timing marks. Listen for any rubbing noises which may mean the belt is binding.
Loosen the tensioner pulley bolt to allow the spring to adjust the correct tension. Then, retighten the tensioner pulley bolt to 14 ft. lbs (19 Nm).
Install the lower timing cover and the crankshaft pulley.
Tighten the crankshaft pulley bolt to 87 ft. lbs. (118 Nm). Tighten the small pulley bolts to 6 ft. lbs. (8 Nm).
Install the upper timing cover.
Install the starter if it was removed. Tighten the bolts to 30 ft. lbs. (40 Nm).
Install the power steering pump. If the hydraulic lines were disconnected, refill and bleed the power steering system.
Install the water pump pulley and tighten its nut to 20 ft. lbs. (26 Nm).
The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing, The water pump is driven by the timing belt and is serviced as a unit.Disconnect battery ground cable.Remove crankshaft drive pulleys and torsional damper,and Right Engine Mount & Bracket.Place a jack under engine to support and slightly raise engine, then remove engine mount bracket. Remove timing belt cover, then mark belt running direction for reinstallation. Loosen timing belt tensioner, then remove belt and crankshaft sprocket flange shield. Drain cooling system. Remove water pump mounting bolts. Separate water pump from water inlet pipe, then remove water pump. Reverse procedure to install, noting the following: Use a new O-ring on water inlet pipe. Torque water pump mounting bolts to 27 Nm (20 ft. lbs.).
First you need to take off all the belts, then remove the a/c line to axcess to the 8 mms bolts holding
the upper and lower timing belt covers. To facilitate the job you will need to remove lower crankshaft pulley. This is a delicate job, since you have to access to the cam belt, I suggest buying the haynes manual for your car and following the step by step illustrated procedure, before starting the job.
3.0l Mitsubishi 6 cylinder.
support engine... remove engine mount... remove alternator, power stearing pump, compressor (if equipt) do not remove hoses from power stearing pump or compressor move them out of the way were they wont get damaged. Remove the tension pulley for the serpentine belt, and the tensioner for the compressor belt if equipt. then remove the compressor mounting bracket. Next remove the engine mounting plate and the crank pulley and balancer assembly. you should now be able to remove the the 3 piece timing cover. Once removed remove the tensioner spring from the water pump and loosen the tensioner nut. Remove the belt. At this point it is also recommended to replace the water pump and plumbing as well. The water pump service life is aproximately the same as the timing belt at 60,000 miles. This engine in stock form is a non interfering type engine. Meaning that moving the cams or crank out of sync will not cause damage. Turn each of the cams over by hand and line them up with the timing mark on the top of the back cover with the marks on the pulleys. Using a wrench turn the crank so that the pulley mark lines up with the mark cast into the block. replace the belt, tensioner spring (replace tensioner if warn) and tighten the tensioner bolt. roll the crank over 2 complete turns forward and recheck the cams to make sure the marks are still lined up. roll the crank backwards and recheck the timing marks again. (this process is much easier done with the plugs removed.) If everything is still lined up correctly (crank at TDC and cam pulleys pointing to each designated mark on the covers.) reassemble the cover and assessorys in the reverse order that they were removed and reinstall the old motor mount or replace if needed.