Mazda B-Series 1998-06

Removal & Installation

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2.3L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the drive belt.
  6.  
  7. Remove the water pump pulley.
  8.  
  9. Remove the water pump.
    NOTE
    Lubricate the water pump O-ring, with MERPOL®.

  10.  
  11. To install, reverse the removal procedure. Torque the water pump mount bolts to 89 inch lbs. (10Nm). Torque the pulley bolts to 18 ft. lbs. (25Nm).
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the drive belt.
  8.  
  9. Remove the water pump pulley.
  10.  
  11. Remove the water pump.

    Click image to see an enlarged view

    Fig. Water pump mounting bolts-2.3L engine

  12.  

To install:

  1. Clean the mating surfaces where the water pump attaches to the engine.
    NOTE
    Lubricate the water pump O-ring, with MERPOL®, or equivalent.

  2.  
  3. To install, reverse the removal procedure. Torque the water pump mount bolts to 89 inch lbs. (10 Nm). Torque the pulley bolts to 18 ft. lbs. (25 Nm).
  4.  

2.5L Engine





Click image to see an enlarged view

Fig. Exploded view of the water pump and related parts for the 2.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


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

  1. Remove the cooling fan and shroud.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the lower radiator hose from the water pump.
  8.  



Click image to see an enlarged view

Fig. Loosen the mounting screws and remove the inlet tube

  1. Disconnect the lower heater water hose from the inlet tube.
  2.  
  3. Loosen the screws and remove the inlet tube.
  4.  
  5. Remove the water pump pulley.
  6.  
  7. Remove the timing belt cover.
  8.  
  9. Remove the water pump mounting bolts and the water pump. Clean all gasket mounting surfaces.
  10.  

To install:



Click image to see an enlarged view

Fig. Apply grease to three locations on the new water pump

  1. Apply grease to three locations on the new water pump, as illustrated.
  2.  
  3. Place the new gasket in position and install the water pump onto the engine. Tighten the water pump mounting bolts to 15-20 ft. lbs. (20-30 Nm).
  4.  
  5. Install the timing belt cover.
  6.  
  7. Install the water pump pulley.
  8.  
  9. Apply grease to the new O-ring seal, install the inlet tube and tighten the mounting screws.
  10.  
  11. Connect the lower heater water hose to the inlet tube. Tighten the hose clamp.
  12.  
  13. Connect the lower radiator hose to the water pump. Tighten the hose clamp.
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the accessory drive belt.
  18.  
  19. Install the cooling fan and shroud.
  20.  
  21. Fill the radiator with the specified amount and type of engine coolant.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks, then bleed the cooling system.
  26.  

  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
     
    Drive belt
     
    Fan clutch and shroud
     
    Water pump pulley
     
    Heater hose from the water pump inlet tube
     
    Lower radiator hose
     
    Water pump inlet tube
     
    Water pump and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the water pump 2.5L engines

     

  6.  

To install:

  1. Clean the mating surface with the water pump connects to the engine.
  2.  
  3. Install or connect the following:

    Water pump with a new O-ring. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Inlet tube. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Lower radiator hose
     
    Water pump pulley
     
    Heater hose from the water pump inlet tube
     
    Fan clutch and shroud
     
    Drive belt
     
    Negative battery cable
     

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

3.0L & 4.0L OHV Engines



  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
     
    Air cleaner outlet tube
     
    Fan and radiator shroud
     
    Water bypass tube
     
    Drive belt
     
    Heater hose
     
    Water pump pulley
     
    Lower radiator hose
     
    A/C compressor and bracket assembly and move them aside
     
    Water pump
     

  6.  

To install:

  1. Clean the mating surfaces where the water pump attaches to the engine.
  2.  
  3. Install or connect the following:

    Water pump. Torque the bolts to 106 in lbs. (12 Nm).
     
    A/C compressor mounting bracket. Torque the bolts to 44 ft. lbs. (61 Nm).
     
    Water pump pulley. Torque the bolts to 20 ft. lbs. (28 Nm).
     
    Drive belt
     
    Heater hose
     
    Lower radiator hose
     
    Fan and shroud
     
    Air cleaner outlet tube
     
    Negative battery cable
     

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

3.0L Engine



  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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 engine fan.
  2.  
  3. Loosen the 4 water pump pulley bolts.
  4.  
  5. Remove the accessory drive belts.
  6.  



Click image to see an enlarged view

Fig. Exploded view of the 3.0L engine water pump

  1. Remove the water pump pulley.
  2.  
  3. Remove the alternator adjusting arm and throttle body brace.
  4.  
  5. Remove the lower radiator hose.
  6.  
  7. Disconnect the heater hose at the pump.
  8.  
  9. Rotate the belt adjuster out of the way.
  10.  
  11. Remove the water pump attaching bolts. Note their location for installation.
  12.  
  13. Remove the pump and discard the gasket.
  14.  
  15. Thoroughly clean the pump and engine mating surfaces.
  16.  

To install:

  1. Using an adhesive type sealer, position a new gasket on the timing cover.
  2.  
  3. Position the water pump and start the bolts. When all the bolts are started, torque them to specifications. Refer to the necessary illustration.
  4.  



Click image to see an enlarged view

Fig. 3.0L engine water pump and front cover fastener chart

  1. Install the lower hose and connect the radiator hose.
  2.  
  3. Install the pulley and hand-tighten the 4 bolts.
  4.  
  5. Install the alternator adjusting arm and brace.
  6.  
  7. Install the belts and tension them. See Section 1.
  8.  
  9. Tighten the 4 pulley bolts to 19 ft. lbs. (26 Nm).
  10.  
  11. Install the fan.
  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Connect the battery ground cable. Run the engine and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner outlet tube
     
    Fan and radiator shroud
     
    Water bypass tube
     
    Drive belt
     
    Heater hose
     
    Water pump pulley
     
    Lower radiator hose
     
    Air conditioning compressor and bracket assembly and move them aside
     
    Water pump

    Click image to see an enlarged view

    Fig. Water pump mounting bolts-3.0L engine

     

  8.  

To install:

  1. Clean the mating surfaces where the water pump attaches to the engine.
  2.  
  3. Install or connect the following:

    Water pump. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Air conditioning compressor mounting bracket. Torque the bolts to 44 ft. lbs. (61 Nm).
     
    Water pump pulley. Torque the bolts to 20 ft. lbs. (28 Nm) for 2002-04 models; 18 ft. lbs. (25 Nm) for 2005-2006 models.
     
    Drive belt
     
    Heater hose
     
    Lower radiator hose
     
    Fan and shroud
     
    Air cleaner outlet tube
     
    Negative battery cable
     

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

4.0L Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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.



Click image to see an enlarged view

Fig. To service the water pump, first drain the cooling system, then remove the engine fan/clutch...



Click image to see an enlarged view

Fig. ... and the fan shroud from the vehicle

  1. Remove the fan and fan clutch assembly.
  2.  

See the engine fan removal procedure in this section.



Click image to see an enlarged view

Fig. Remove the lower radiator hose from the water pump. Position a drain pan underneath to catch any coolant

  1. Remove the lower radiator hose from the water pump.
  2.  



Click image to see an enlarged view

Fig. Loosen the water pump pulley attaching bolts ...



Click image to see an enlarged view

Fig. ... before removing the accessory drive belt ...

  1. Loosen the water pump pulley attaching bolts.
  2.  
  3. Loosen the alternator mounting bolts and remove the belt. On vehicles with air conditioning, remove the tensioner pulley, alternator and bracket.
  4.  
  5. Remove the A/C compressor and power steering pump mounting bracket, without disconnecting the lines, and set off to the side.
  6.  



Click image to see an enlarged view

Fig. ... then with the drive belt out of the way, finish removing the water pump pulley

  1. Remove the water pump pulley.
  2.  
  3. Disconnect the heater hose at the pump.
  4.  



Click image to see an enlarged view

Fig. Remove the heater hose connection at the water pump



Click image to see an enlarged view

Fig. Remove all of the water pump attaching bolts ...



Click image to see an enlarged view

Fig. ... then remove the pump from the engine

  1. Remove the attaching bolts and remove the water pump.
  2.  

To install:

  1. Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket material.
  2.  



Click image to see an enlarged view

Fig. Remove all traces of the old gasket before installing the pump

  1. Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump.
  2.  
  3. Position the pump on the cover and install the bolts finger-tight. When all bolts are in place, torque them to 72-108 inch lbs. (9-12 Nm).
  4.  
  5. Install the pulley.
  6.  
  7. On vehicles with air conditioning, install the alternator, bracket and tensioner pulley.
  8.  
  9. Install the A/C compressor and power steering pump mounting bracket.
  10.  
  11. Install and adjust the drive belt.
  12.  
  13. Connect the hoses and tighten the clamps.
  14.  
  15. Install the fan and clutch assembly.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Connect the negative battery cable, then start the engine and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Fan shroud
     
    Accessory drive belt
     
    Idler pulley
     
    Water bypass hose
     
    Heater hose
     
    Lower radiator hose
     
    Water pump pulley
     
    Water pump
     

  8.  

To install:

Click image to see an enlarged view

Fig. Water pump mounting bolts-4.0L engine

  1. Clean the mating surfaces where the water pump attaches to the engine.
    WARNING
    Use care when scraping the water pump-to-engine block mating surfaces. Gouges in the aluminum could form leak paths.

  2.  
  3. Clean all the sealing surfaces.
  4.  
  5. To install, reverse the removal procedure. Torque the water pump bolts to 89 inch lbs. (10 Nm). Torque the pulley bolts to 18 ft. lbs. (25 Nm).
  6.  

SOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Use care when scraping the water pump-to-engine block mating surfaces. Gouges in the aluminum could form leak paths.



    Fan shroud
     
    Accessory drive belt
     
    Idler pulley
     
    Water bypass hose
     
    Heater hose
     
    Lower radiator hose
     
    Water pump pulley
     
    Water pump
     

  6.  
  7. Clean all the sealing surfaces.
  8.  
  9. To install, reverse the removal procedure. Torque the water pump bolts to 89 inch lbs. (10Nm). Torque the pulley bolts to 18 ft. lbs. (25Nm).
  10.  

 
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