Question about 2003 Suzuki VL 800 Volusia

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How can I install a water pump?

When trying to install a new water pump, in order to get the mounting holes aligned the shaft of the water pump does not align with the slot on the oil pump shaft. How can I get the oil pump shaft to move so the two shafts can align to get the new water pump installed?

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How can I remove the water pump?

https://www.manualslib.com/manual/1042330/Suzuki-Vl800.html?page=172
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2003 Suzuki VL 800 Volusia how to check the coolant level

You have to remove the cover on the lower left side of the motorcycle, then you can observe the coolant level indicator. See the link below.

Cooling System - Suzuki VL800 Service Manual [Page 29] ' ManualsLib
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WHER IS THE WATER PUMP

Try Chilton's or All Data for instructions. This is a 4.5 -5 hour ordeal for a professional and a 2 day mess for an amateur. Plus you must remove the timing belt on the 2.4L 4 Cylinder to get to the pump. Mess up here and you can damage your engine. WATER PUMP is sign with the ITEM 5 in the next diagram...

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  1. Disconnect the negative battery cable.
This procedure requires removing the engine timing belt and the auto tensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at TDC on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

  1. Raise and safely support the vehicle to a level that allows access from above and below.
  2. Remove the right inner splash shield.
  3. Remove the accessory drive belts.
  4. Place a drain pan under the radiator drain plug. Drain and properly contain the cooling system.
  5. Support the engine using a floor jack and block of wood, then remove the right motor mount.
  6. Remove the timing belt, tensioner and camshaft sprockets.

WARNING With the timing belt removed, DO NOT rotate the camshaft or crankshaft, or damage to the engine could occur.

  1. Remove the rear timing belt cover to access the water pump.
  2. Remove the water pump attaching bolts.
  3. Remove the water pump.
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Fig. 1: Water pump location on the cylinder block-4-cylinder engines





Fig. 2: Water pump assembly-4-cylinder engines


To install:

  1. Thoroughly clean all sealing surfaces. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, a damaged impeller or sprocket, or a loose or damaged sprocket flange.
  2. Install a new rubber O-ring into the water pump.
Make sure the O-ring is properly seated in the water pump groove before tightening the screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.

  1. Install the water pump and tighten the bolts to 105 inch lbs. (12 Nm).
  2. Using a cooling system pressure tester, pressurize the cooling system to 15 psi and check for leaks. If okay, release the pressure and continue the engine assembly process.
  3. Rotate the water pump by hand to check for freedom of movement.
  4. Install the rear timing belt cover.
  5. Install the camshaft sprocket(s), timing belt and tensioner. DO NOT allow the camshafts to turn while the sprocket bolts are being tightened, in order to maintain timing mark alignment.

WARNING Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise.

  1. Install the timing belt covers.
  2. Install the right engine mount bracket and engine mount.
  3. Remove the floor jack and wood block from underneath the engine.
  4. Install the crankshaft damper.
  5. Install the right inner splash shield.
  6. Lower the vehicle.
  7. Install and tension the accessory drive belts.
  8. Refill the cooling system using the correct quantity and type of coolant. Bleed the cooling system.
  9. Start the engine and check for proper operation.
  10. Check and top off the cooling system, if necessary.
2.5L Engine
See Figures 3 through 7

  1. Disconnect the negative battery cable.
  2. 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.

  1. Remove the accessory drive belts and crankshaft damper.
  2. Remove the right engine mount. This requires safely supporting the engine with a floor jack and wood block so the mount can be removed.
  3. Remove the timing belt covers.
  4. Remove the timing belt and tensioner.

Fig. 3: Remove the water pump mounting bolts



Fig. 4: Pull the water pump assembly off of the engine and inlet pipe



Fig. 5: Open the water pump housing and examine for cracks or damage



Fig. 6: Replace the water pump housing gasket using a scraper tool



Fig. 7: Always keep the water pump's mounting bolts lined up with their correct mounting holes



  1. Remove the water pump mounting bolts.
  2. Separate the water pump from the water inlet pipe and remove the pump.
To install:

  1. 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.
  2. 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.
  3. 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.
  4. Install the water pump-to-engine bolts and tighten to 20 ft. lbs. (27 Nm).
  5. Install the timing belt and timing belt tensioner. Set the timing belt tension.
  6. Install the timing belt covers. Install the right engine mount. Remove the floor jack and engine block from underneath the engine.
  7. Install the crankshaft damper.
  8. Install the accessory drive belts and set to the proper tension.
  9. Connect the negative battery cable.
  10. Fill and bleed the engine cooling system.
  11. Start the engine and verify proper operation, with no leaks.

Hope this helps (remember to rate this answer).
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I have a 2003 VL 800 Suzuki. I have oil leaking from behind the water pump housing. And yes it is coming out of the small hole behind the water pump. Could this be the oil seal on the water pump? Steve

yes steve- this is the water pump by-pass hole. There is a secondary backup al behind it to stop the water entring the gearbox. Replace the waterpump seal. Most suzukis' use a mechanical seal. they are prity easy to change- although usually requires removal of the clutch cover. I always replace the mechanical seal, back up seal & the bearing all at once.If it is a standard seal type- be sure to ckeck the shaft of the impellor for groves worn in it where the seal contacts the shaft - in mechanical type seals this does not apply.
Hope this helps regards
Andrew
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Timming bailt marks for 1990 plym laser rs

REMOVAL & INSTALLATION 1.8L Engine
  1. If possible, position the engine so the No. 1 piston is at TDC.
  2. Disconnect the negative battery cable.
  3. Remove the timing belt covers.
  4. Remove the timing (outer) belt tensioner and remove the outer timing belt.
  5. Remove the outer crankshaft sprocket and flange.
  6. Remove the silent shaft (inner) belt tensioner and remove the belt. Fig. 1: Silent shaft belt timing marks — 1.8L engine 89573g93.gif
    Fig. 2: Checking the silent shafts for proper positioning 89573g94.gif
    Fig. 3: Timing belt timing mark alignment — 1.8L engine 89573g95.gif
    To install:
  7. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.
  8. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about 1⁄4 in.
  9. Hold the pulley tightly so the pulley cannot rotate when the bolt is tigthened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the deflection amount.
  10. Install the timing belt tensioner fully toward the water pump and tighten the bolts. Place the upper end of the spring against the water pump body.
  11. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover. NOTE: There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.
  12. Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
    1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
    2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 1/2 in. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 1/3 in.
    3. Recheck and realign the timing mark.
    4. Leave the tool in place to hold the silent shaft while continuing.
  13. Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprocket except where the tensioner is installed.
  14. Recheck the timing marks' alignment. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.
  15. Remove the tool that is holding the silent shaft and rotate the crankshaft a distance equal to 2 teeth on the camshaft sprocket. This will allow the tensioner to automatically apply the proper tension on the belt. Do not manually overtigthen the belt or it will howl.
  16. Tigthen the lower mounting bolt first, then the upper spacer bolt.
  17. To verify correct belt tension, check that the deflection at the longest span of the belt is about 1⁄2 in.
  18. Install the timing belt covers and all related items.
  19. Connect the negative battery cable.
4helpful
1answer

How install timing belt 1993 1.8l eclipse

See Figures 1, 2 and 3
  1. If possible, position the engine so the No. 1 piston is at TDC.
  2. Disconnect the negative battery cable.
  3. Remove the timing belt covers.
  4. Remove the timing (outer) belt tensioner and remove the outer timing belt.
  5. Remove the outer crankshaft sprocket and flange.
  6. Remove the silent shaft (inner) belt tensioner and remove the belt.
0900c152800ad6b2.jpgFig. 1: Silent shaft belt timing marks-1.8L engine 0900c152800ad6b3.jpgFig. 2: Checking the silent shafts for proper positioning 0900c152800ad6b4.jpgFig. 3: Timing belt timing mark alignment-1.8L engineTo install:
  1. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.
  2. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about 1/4in.
  3. Hold the pulley tightly so the pulley cannot rotate when the bolt is tigthened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the deflection amount.
  4. Install the timing belt tensioner fully toward the water pump and tighten the bolts. Place the upper end of the spring against the water pump body.
  5. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.
There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.
  1. Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
    1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
    2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 1/2 in. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 1/3 in.
    3. Recheck and realign the timing mark.
    4. Leave the tool in place to hold the silent shaft while continuing.
  2. Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprocket except where the tensioner is installed.
  3. Recheck the timing marks' alignment. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.
  4. Remove the tool that is holding the silent shaft and rotate the crankshaft a distance equal to 2 teeth on the camshaft sprocket. This will allow the tensioner to automatically apply the proper tension on the belt. Do not manually overtigthen the belt or it will howl.
  5. Tigthen the lower mounting bolt first, then the upper spacer bolt.
  6. To verify correct belt tension, check that the deflection at the longest span of the belt is about 1/2in.
  7. Install the timing belt covers and all related items.
  8. Connect the negative battery cable.
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