Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



During these procedures, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

1.3L and 1.6L Engines

See Figures 1 through 7

  1. Remove the timing belt cover, timing belt, tensioner, plate and spring.
  2.  
  3. Remove the water pump mounting bolts.
  4.  
  5. Remove the one (1.6L MFI engines) or two (1.3L and 1.6L TFI engines) small rubber seals from between the water pump and the oil pump, and the water pump and the cylinder head.
  6.  
  7. If necessary for clearance, remove the oil level dipstick tube retaining bolt from the engine block and the alternator adjusting brace.
  8.  



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Fig. Fig. 1: Exploded view of the water pump mounting


WARNING
Do NOT use a prybar between the water pump housing and the engine block to separate the two components; this can cause scratches and/or gouges, which can prevent proper sealing.

  1. Pull the water pump off of the engine block. If the water pump is difficult to remove from the engine block, use a soft-faced mallet to tap the water pump housing until it loosens.
  2.  

Do not disassemble the water pump; if the water pump is damaged or defective, the entire unit is replaced.

  1. Thoroughly clean the water pump gasket mating surfaces of old gasket material and corrosion.
  2.  



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Fig. Fig. 2: The drive belt can be used to hold the fan stable while loosening the mounting fasteners



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Fig. Fig. 3: Loosen the fan bolts, then either remove the drive belt before the fan and shroud ...



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Fig. Fig. 4: ... or wait to remove the belt, along with the water pump pulley



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Fig. Fig. 5: Once the cooling fan and shroud are removed, access can be gained to many of the engine components, including the water pump

To install:
  1. Along with a new gasket, install the water pump on the engine block. Tighten the water pump mounting bolts to 88-115 inch lbs. (10-13 Nm).
  2.  
  3. On 1.3L and TFI 1.6L engines, install two new rubber seals: one between the water pump and oil pump, and the other between the water pump and the cylinder head. The MFI 1.6L engines only use one rubber seal, located between the water and oil pumps.
  4.  



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Fig. Fig. 6: Be sure to install the two rubber seals between the water pump, oil pump and cylinder head before installing the timing belt cover-1.3L and 1.6L TFI engines



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Fig. Fig. 7: The 1.6L MFI engine uses only one rubber seal between the oil pump and water pump

  1. If removed, install the alternator adjusting brace and the oil level dipstick retaining bolt.
  2.  
  3. Install the timing belt, tensioner, plate, spring and cover.
  4.  

1.8L Engine

See Figures 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disconnect the upper radiator hose from the thermostat housing.
  6.  
  7. Remove the heater outlet pipe bolt.
  8.  



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Fig. Fig. 8: The water pump is mounted next to the thermostat housing

  1. Remove the alternator belt.
  2.  

When removing the water pump, do not misplace the dowel pin.

  1. Remove the four water pump mounting bolts, then remove the water pump from the engine. Discard the old water pump mounting bolts.
  2.  
  3. Remove the water pump O-ring and discard it.
  4.  

To install:
  1. Install a new O-ring on the water pump, and ensure that the dowel pins are still mounted in the water pump prior to installation.
  2.  
  3. Position the water pump on the engine and install NEW mounting bolts. Tighten the bolts to 221 inch lbs. (25 Nm). Failure to use four new bolts when installing the water pump may lead to coolant leakage.
  4.  



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Fig. Fig. 9: Be sure to install a new O-ring in the water pump prior to installation, otherwise coolant leakage may occur

  1. Install the heater outlet pipe bolt.
  2.  
  3. Install the alternator drive belt.
  4.  
  5. Reattach the upper radiator hose to the thermostat housing.
  6.  
  7. Fill the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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