Water Pump: Removal and Installation: Removal

WARNING: This page is about a different variant/trim than selected.

Drain engine coolant from radiator. Refer to Engine Coolant: System Inspection .
CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on timing chain and drive belt.
Remove water drain plug (front) (1) on the water pump side of the cylinder block.

Fig 1: Identifying Water Drain Plug (Front) (1)
Courtesy of SUZUKI OF AMERICA CORP.
Remove coolant reservoir hose from the radiator.
Remove engine cooling fan (Motor driven type). Refer to Engine Cooling Fan: Removal and Installation (Motor driven type)
Remove engine cooling fan (Crankshaft driven type) and fan bracket. Refer to ENGINE COOLING FAN: REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE) .
Set No. 1 cylinder at TDC.
- Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).
  
  Fig 2: Identifying Crankshaft Pulley Align Timing Marks & Timing Indicator
  Courtesy of SUZUKI OF AMERICA CORP.
Remove chain tensioner cover and water pump cover from front timing chain case, using Tool.

Fig 3: Identifying Chain Tensioner Cover And Water Pump Cover
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: KV10111100 (J-37228)
Remove timing chain tensioner (primary) as follows:
1. Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).
  
  Fig 4: Locating Plunger Stopper, Slack Guide And Plunger Groove
  Courtesy of SUZUKI OF AMERICA CORP.
2. Insert plunger into tensioner body by pressing slack guide (2).
3. Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove (3).
4. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.
  
  Fig 5: Turning Crankshaft Pulley Clockwise
  Courtesy of SUZUKI OF AMERICA CORP.
5. Remove bolts and remove timing chain tensioner (primary).
  
  Fig 6: Removing Timing Chain Tensioner (Primary)
  Courtesy of SUZUKI OF AMERICA CORP.
  
  CAUTION: Be careful not to drop bolts inside timing chain case.
Remove water pump as follows:
1. Remove three water pump bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum.
  
  Fig 7: Turning Crankshaft Pulley Counterclockwise
  Courtesy of SUZUKI OF AMERICA CORP.
2. Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: approx. 50 mm (1.97 in) ] into water pumps upper and lower bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump.
  
  Fig 8: Tightening Water Pumps Upper And Lower Bolt
  Courtesy of SUZUKI OF AMERICA CORP.
  CAUTION:
  - Place a suitable shop cloth below the water pump housing to prevent any engine coolant from dripping into the timing chain case.
  - Pull water pump straight out while preventing vane from contacting socket in installation area.
  - Remove water pump without causing sprocket to contact timing chain.
3. Remove M8 bolts and O-rings from water pump.
  CAUTION: Do not disassemble water pump.
  
  NOTE: Do not reuse O-rings.