[1] – Park machine safely.
[2] – Allow engine to cool before servicing cooling system.
[3] – Open radiator cap.
[4] –
→NOTE:
Place a suitable container under radiator drain hose. Open radiator drain valve (A) and drain the coolant.
[5] – Place a suitable container under engine block drain plug (B) and remove plug.
[6] – Loosen clamp (C). Remove cap screws (D) and remove air cleaner and intake hose assembly.
[7] – Loosen hose clamps (E) and (F) and disconnect radiator hoses from water pump.
Disconnect temperature sensor wire (G).
[8] – Remove nut and washer (H) and cap screws and nuts (I). Remove radiator support rod.
[9] – Remove clamp (J) and cap screw (K) Remove exhaust pipe.
[10] – Remove alternator bracket (L). Pivot alternator clear of the water pump.
[11] – Remove two cap screws (M) from left side of water pump.
[12] – Remove the remaining water pump mounting cap screw (N) from the right side.
[13] – Use care not to damage fan blades. Pull water pump assembly out toward right side of machine.
[14] – Clean cylinder block mating surfaces of all old gasket material.
[15] – Inspect the water pump for coolant leakage.
a. If coolant is leaking at the bottom of the shaft housing the shaft seal is defective.
Replace the water pump.
b. If coolant is leaking between the cylinder head and the pump housing the gasket
between the head and the pump is defective. Replace the gasket.
[16] – Inspect the water pump for a worn bearing shaft. Check for side to side movement of the shaft. If shaft can be moved replace the water pump.
[17] – Install the water pump.
a. Make sure all sealing areas are clean and free of any old gasket material.
b. Install new gasket and O-ring on water pump.
c. Install water pump and tighten cap screws to specification.
d. Install alternator bracket and install belt. Adjust belt tension.
e. Install support rod, air cleaner assembly, and exhaust pipe.
f. Install block drain plug.
g. Close drain valves. Fill radiator to top of filler neck with proper coolant.
h. Fill coolant reservoir between the full cold and full hot marks.
i. Start engine. Allow it to reach proper operating temperature. Check radiator, hoses and connections for leaks. Allow engine to cool, then check and adjust coolant level in recovery tank as needed.
