Hyundai Car 1999-05

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Water pump pulley
     
    Timing belt, tensioner and idler pulley
     
    Water pump
     

  6.  


    Click image to see an enlarged view

    Fig. Water pump assembly-XG 300 and XG 350


To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Water pump with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Tensioner and timing belt and idler pulley
     
    Water pump pulley and drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.5L engines



Click image to see an enlarged view

Fig. Water pump bolt lengths-1.5L-1.6L engines



Click image to see an enlarged view

Fig. Water pump assembly-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly and related components-2.0L engines



Click image to see an enlarged view

Fig. Water pump assembly-3.0L engine Sonata



Click image to see an enlarged view

Fig. Water pump bolt lengths-3.0L Sonata

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The water pump bolts are different lengths. Note the bolt location for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Radiator hose
     
    Bypass hose, if equipped
     
    Water pump pulley
     
    Front cover
     
    Timing belt
     
    Alternator bracket
     
    Water pump
     

  6.  

To install:

  1. Install the water pump with new gaskets and O-rings. Tighten the bolts to the following specifications:
    1. 1.5L SOHC engine: 105-132 inch lbs. (12-15 Nm).
    2.  
    3. 1.5L DOHC engine: 14-20 ft. lbs. (20-27 Nm).
    4.  
    5. 1.6L DOHC engine: 14-20 ft. lbs. (20-27 Nm).
    6.  
    7. 1.8L, 2.0L, and 2.4L engines: 14-20 ft. lbs. (20-27 Nm).
    8.  
    9. 2.5L engine: 11-16 ft. lbs. (15-22 Nm).
    10.  

  2.  
  3. Install or connect the following:

    Alternator bracket
     
    Timing belt and front cover
     
    Water pump pulley
     
    Bypass hose, if equipped
     
    Radiator hose
     
    Accessory drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the engine and check for leaks.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.5L engines



Click image to see an enlarged view

Fig. Water pump bolt lengths-1.5L-1.6L engines



Click image to see an enlarged view

Fig. Water pump assembly-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly and related components-2.0L engines



Click image to see an enlarged view

Fig. Water pump assembly-3.0L engine Sonata



Click image to see an enlarged view

Fig. Water pump bolt lengths-3.0L Sonata



Click image to see an enlarged view

Fig. Water pump assembly- 3.5L engine



Click image to see an enlarged view

Fig. Water pump bolt lengths-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The water pump bolts are different lengths. Note the bolt location for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Radiator hose
     
    Bypass hose, if equipped
     
    Water pump pulley
     
    Front cover
     
    Timing belt
     
    Alternator bracket
     
    Water pump
     

  6.  

To install:

  1. Install the water pump with new gaskets and O-rings. Tighten the bolts to the following specifications:
    1. 1.5L SOHC engine: 105-132 inch lbs. (12-15 Nm).
    2.  
    3. 1.5L DOHC engine: 14-20 ft. lbs. (20-27 Nm).
    4.  
    5. 1.6L DOHC engine: 14-20 ft. lbs. (20-27 Nm).
    6.  
    7. 1.8L, 2.0L, and 2.4L engines: 14-20 ft. lbs. (20-27 Nm).
    8.  
    9. 2.5L engine: 11-16 ft. lbs. (15-22 Nm).
    10.  

  2.  
  3. Install or connect the following:

    Alternator bracket
     
    Timing belt and front cover
     
    Water pump pulley
     
    Bypass hose, if equipped
     
    Radiator hose
     
    Accessory drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Water pump pulley
     
    Timing belt, tensioner and idler pulley
     
    Water pump

    Click image to see an enlarged view

    Fig. Water pump assembly-XG 300

     

  6.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Water pump with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Tensioner and timing belt and idler pulley
     
    Water pump pulley and drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Water pump pulley
     
    Timing belt, tensioner and idler pulley
     
    Water pump

    Click image to see an enlarged view

    Fig. Water pump assembly-XG 350

     

  6.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Water pump with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Tensioner and timing belt and idler pulley
     
    Water pump pulley and drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

 
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