Isuzu Cars and Trucks 1981-1991

Water Pump

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REMOVAL AND INSTALLATION
G180Z and G200Z Engine

NOTE
This procedure may be easier if the radiator and shroud is removed. If the radiator is not removed, place cardboard in front so not to damage the radiator core

  1. Open the hood and disconnect the battery. Remove the lower engine cover.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. On cars without air conditioning, remove the fan.
  2.  
  3. On cars with air conditioning, remove the air pump and generator mounting bolts, then remove the fan and air pump drive belt (pivot the generator and air pump in toward the engine). Remove the fan and pulley with set plate. Remove the hoses to the pump.
  4.  
  5. Remove the 6 bolts attaching the water pump and remove the water pump assembly. Clean all gasket surfaces carefully.
  6.  



Click image to see an enlarged view

Fig. Water pump assembly G180Z and G200Z engines

To install:

  1. Install the 6 bolts attaching the water pump with a new gasket.
  2.  
  3. On cars with air conditioning, install the air pump and generator mounting bolts, then install the fan and air pump drive belt (pivot the generator and air pump in toward the engine). Install the fan and pulley with set plate. Install the hoses to the pump.
  4.  
  5. On cars without air conditioning, install the fan.
  6.  
  7. Refill the cooling system.
  8.  
  9. Connect the battery, start the engine and check for leaks.
  10.  

4XC1-U, 4XC1-T and 4XE1 DOHC Engines
  1. Disconnect the negative battery cable and drain the coolant into a suitable drain pan.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the power steering pump adjustment bolts and remove the belt. (Remove all necessary drive belts).
  2.  
  3. Remove the timing belt as previously outlined in this section.
  4.  
  5. Remove the tension pulley and spring. Remove the water pump pulley.
  6.  
  7. Remove the water pump mounting bolts, water pump and gasket from the engine. Clean the mounting surfaces of all gasket material.
  8.  



Click image to see an enlarged view

Fig. Water pump assembly 4XC1-U, 4XC1-T and 4XE1 engines

To install:

  1. Apply a suitable sealant to the mounting surfaces of the pump and torque the pump to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the tension pulley and spring. Install the water pump pulley.
  4.  
  5. Install the timing belt as previously outlined in this section.
  6.  
  7. Install the belt and tighten the power steering pump adjustment bolts.
  8.  
  9. Connect the negative battery cable and refill the coolant. Start the engine and check for leaks.
  10.  

4ZC1-T and 4ZD1 Engines
  1. Disconnect the battery and drain the radiator.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the fan belt, plate, spacer, and pulley.
  2.  
  3. Remove the water pump and gasket.
  4.  

To install:

  1. Before installation, clean the gasket surfaces carefully and torque the water pump retaining bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the fan belt, plate, spacer, and pulley.
  4.  
  5. Connect the battery, refill the radiator, start the engine and check for leaks.
  6.  

4FB1 Diesel Engine
  1. Open the hood and disconnect the battery. Remove the radiator cap.
  2.  
  3. Drain the cooling system and remove the hoses from the pump.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the fan and pulley.
  2.  
  3. Remove the four attaching bolts holding the damper pulley. Remove the damper pulley.
  4.  
  5. Remove the engine dust covers.
  6.  
  7. Remove the bypass hose.
  8.  
  9. Remove the five bolts attaching the water pump and remove the pump and gasket.
  10.  



Click image to see an enlarged view

Fig. Water pump assembly 4FB1 diesel engine

To install:

  1. Clean all gasket surfaces carefully and inspect for nicks, cracks or deep scratches.
  2.  
  3. Use a new gasket. Torque all water pump mounting bolts to 11 and 1918 ft. lbs. (15 and 1923 Nm).
  4.  
  5. Install the bypass hose.
  6.  
  7. Install the engine dust covers.
  8.  
  9. Install the four attaching bolts holding the damper pulley and damper pulley.
  10.  
  11. Install the fan and pulley.
  12.  
  13. Install the hoses to the water pump and refill the cooling system.
  14.  
  15. Connect the battery, install the radiator cap, start the engine and check for leaks.
  16.  

4ZE1 Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the undercover, if equipped, and drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the drive belt from the water pump pulley.
  2.  
  3. Remove the coolant hose from the pump body, if so equipped.
  4.  
  5. Remove the fan blade and pulley from the pump hub.
  6.  
  7. Remove the water pump-to-engine bolts, the water pump and gasket.
  8.  
  9. Clean and inspect the mounting surfaces of the water pump and engine.
  10.  

To install:

  1. Install a new gasket and the water pump; torque the water pump-to-engine bolts to 24 and 1938 ft. lbs. (33 and 1952 Nm).
  2.  
  3. Install the fan blade and pulley to the water pump.
  4.  
  5. Connect the water hose to the pump, if so equipped.
  6.  
  7. Install and adjust the drive belt.
  8.  
  9. Refill the cooling system and install the undercover, if equipped.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Operate the engine to normal operating temperatures and check for leaks.
  14.  

V6 Engine
  1. Disconnect the negative battery terminal.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the fan shroud and/or radiator support, as applicable.
  2.  
  3. Remove all drive belts.
  4.  
  5. Remove the fan and pulley from the water pump.
  6.  
  7. Remove the alternator upper and lower brackets. Remove the power steering pump lower bracket and swing aside.
  8.  
  9. Remove the bottom radiator hose and heater hose from the pump.
  10.  
  11. Remove the water pump.
  12.  



Click image to see an enlarged view

Fig. Water pump assembly V6 engine

To install:

  1. Clean the gasket mating surfaces with solvent and a scraper.
  2.  
  3. Coat the new gasket with RTV Sealer.
  4.  
  5. Install the gasket, pump and bolts. Torque the pump bolts 15 and 1925 ft. lbs. (20 and 1934 Nm).
  6.  
  7. Install the bottom radiator hose and heater hose to the pump.
  8.  
  9. Install the alternator upper and lower brackets. Install the power steering pump lower bracket.
  10.  
  11. Install the fan and pulley to the water pump.
  12.  
  13. Install all drive belts.
  14.  
  15. Install the fan shroud and/or radiator support, as applicable.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery terminal. Start the engine and check for leaks.
  20.  

 
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