Hyundai Coupes/Sedans 1986-1993 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



1468cc and 1495cc Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 1: Water pump and cooling system components-1986-89 1468cc engine



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Fig. Fig. 2: Water pump mounting-1990-93 1468cc engine

  1. Loosen the 4 bolts attaching the water pump pulley to the pulley flange. Loosen the alternator mounting bolts, slide the alternator toward the engine and remove the belt. Remove the radiator cap, open the draincock at the bottom of the radiator and drain the coolant from the radiator into a clean container.
  2.  
  3. Remove the timing belt covers, timing belt and tensioner.
  4.  
  5. Remove the water pump mounting bolts, noting the 3 different lengths and locations. Remove the pump and gasket, disconnecting the outlet at the water pipe (don't lose the O-ring).
  6.  

To install:
  1. Clean gasket surfaces and coat a new gasket with sealer. Then, position the gasket on the front of the block with all bolt holes aligned. Replace the O-ring for the outlet water pipe.
  2.  
  3. Install the pump connecting the outlet water pipe. Install the bolts with the shortest at the bottom; 2 just slightly longer at the 1 and 4 o'clock positions on the right side of the pump; next-to-longest bolt at the 8 o'clock position, just under the outlet; and the longest bolt at the 11 o'clock position and also attaching the alternator brace. Torque the bolts with a head mark 4, to 9-11 ft. lbs. (12-15 Nm); those with a head mark 7, to 14-20 ft. lbs. (20-26 Nm).
  4.  
  5. Install the remaining parts in reverse order. Final tightening of the water pump pulley bolts is done after the V-belt has been installed and tensioned. Recheck tension after the pulley bolts are tightened. Close the radiator drain and refill the system. Run the engine until the thermostat opens and then add coolant until the level stabilizes before replacing the radiator cap. Check for leaks. Connect the negative battery cable.
  6.  

1596cc, 1796cc and 1997cc Engines

See Figure 3

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  



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Fig. Fig. 3: Water pump removal and mounting-1596cc, 1796cc and 1997cc engines

  1. Remove all drive belts and water pump pulley.
  2.  
  3. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. Remove the timing belt covers and the timing belt tensioner.
  4.  
  5. Remove the water pump mounting bolts and the alternator mounting brace.
  6.  
  7. Remove the water pump assembly from the engine block.
  8.  
  9. Thoroughly clean all gasket mounting surfaces to prevent leaks after reassembly.
  10.  

To install:
  1. Install new O-rings on the front end of the water pipe, then wet the O-ring with water to aid in installation. Do not apply oil or grease to the O-ring.
  2.  
  3. Install the water pump onto the block with a new gasket in place. Position the alternator brace on pump and install the mounting screws. Tighten mounting bolts as follows:
    1. Head mark 4 bolt-9-11 ft. lbs. (12-15 Nm)
    2.  
    3. Head mark 7 bolt-14-20 ft. lbs. (20-27 Nm)
    4.  

  4.  
  5. Install the timing belt tensioner and the timing belt. Install the timing belt front covers.
  6.  
  7. Install the water pump pulley and drive belts. Adjust the drive belt tension.
  8.  
  9. Refill the cooling system and reconnect the negative battery cable.
  10.  
  11. Start the vehicle and run until normal operating temperature is reached. Check the operation of the heating system and inspect for leaks.
  12.  
  13. Shut the engine OFF and allow to cool. Carefully remove the radiator cap. Add coolant as required to fill the system to the appropriate level.
  14.  

2351cc Engine

See Figure 4



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Fig. Fig. 4: Water pump mounting-2351cc engine

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove all drive belts and the water pump pulley.
  4.  
  5. Remove the timing belt covers, timing belt tensioner and timing belt.
  6.  
  7. Remove the water pump mounting bolts.
  8.  
  9. Remove the water pump from the engine block.
  10.  

The pump is not rebuildable. If there are signs of damage or leakage from the seals or vent hole, the unit must be replaced.

  1. Discard the O-ring in the front end of the water pipe. Install a new O-ring coated with water.
  2.  
  3. Using a new gasket, mount the water pump. Torque the bolts with a head marked 4, to 10 ft. lbs. (14 Nm) or the bolts with a head marked 7, to 20 ft. lbs. (27 Nm).
  4.  
  5. Install the timing belt tensioner, timing belt and belt covers.
  6.  
  7. Install the water pump pulley and accessory drive belts.
  8.  
  9. Connect the negative battery cable and fill the cooling system to the proper level.
  10.  
  11. Start the vehicle and run until normal operating temperature is reached. Check the operation of the heating system and inspect for leaks.
  12.  
  13. Shut the engine OFF and allow to cool. Carefully remove the radiator cap. Add coolant as required to fill the system to the appropriate level.
  14.  

2972cc Engine

See Figures 5, 6 and 7



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Fig. Fig. 5: Water pump removal and mounting-2972cc engine



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Fig. Fig. 6: Water pump O-ring installation



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Fig. Fig. 7: Water pump bolt locations and lengths-2972cc engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the timing cover. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Make sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprocket timing marks are aligned with the engine's timing mark indicators.
  6.  
  7. Loosen the timing belt tensioner bolt and remove the belt. Position the tensioner as far away from the center of the engine as possible and tighten the bolt. Remove the water pump mounting bolts, separate the pump from the water inlet pipe and remove the pump from the engine.
  8.  

To install:
  1. Install the pump with a new gasket to the engine. Torque the water pump mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. If not already done, position both camshafts so the marks align with those on the alternator bracket (rear bank) and inner timing cover (front bank). Rotate the crankshaft so the timing mark aligns with the mark on the oil pump.
  4.  
  5. Install the timing belt on the crankshaft sprocket and while keeping the belt tight on the tension side (right side), install the belt on the front camshaft sprocket.
  6.  
  7. Install the belt on the water pump pulley, then the rear camshaft sprocket and the tensioner.
  8.  
  9. Rotate the front camshaft counterclockwise to tension the belt between the front camshaft and the crankshaft. If the timing marks became misaligned, repeat the procedure.
  10.  
  11. Install the crankshaft sprocket flange.
  12.  
  13. Loosen the tensioner bolt and allow the spring to tension the belt.
  14.  
  15. Turn the crankshaft 2 full turns in the clockwise direction only until the timing marks align again. Now that the belt is properly tensioned, torque the tensioner lock bolt to 21 ft. lbs. (29 Nm).
  16.  
  17. Refill the cooling system. Connect the negative battery cable and road test the vehicle.
  18.  

 
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