101601-5411 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1016015411 220006120a

2. Loosen the clamps on breather tube (1), and pull it back for clearance. 3. Remove bolt (2) from the cover on the side of the cylinder block. 4. Remove the three bolts that hold cover (3) to the water pump. Remove cover (3) from the water pump. 5. Remove two bolts (4), and remove bonnet (5). 6. Remove six bolts (6) that hold the water pump to the timing gear cover. Remove the water pump.7. Check the O-ring seals and gaskets, and make replacements if needed.For the installation of the water pump reverse the removal procedures.8. See Maintenance Manual for coolant refill.End By:a. remove alternator and mounting groupb. remove water temperature regulator and manifoldDisassemble & Assemble Water Pump
Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing. 1. Remove O-ring seal (3) from adapter (4). Remove the adapter from housing (7). Remove the O-ring seal from the outside of the adapter.2. Remove bolt (1) and washer (2). Use tooling (A) to remove impeller (6) from shaft (13).3. Remove spring and seal (5) from the shaft.4. Remove four bolts (16) from retainer (12) that hold the shaft assembly to the pump housing. Remove O-ring seal (18) from housing (7).5. Remove gear and shaft assembly (17) from the housing. Remove bolt (15), retainer (14), and retainer (12) from the shaft assembly.6. Use a press to remove shaft (13) from the gear. Remove bearing (9), spacer (10), and bearing (11) from the shaft.7. Remove lip-type seal (8) from the housing.8. Turn the housing over, and remove ceramic ring (20) and seal (19) from the housing. The following steps are for the assembly of the water pump.9. Use 6V1541 Quick Cure Primer and clean shaft (13) and the seal counter bore in the pump housing.10. Install bearing (9), spacer (10), and bearing (11) on shaft (13).11. Put retainer (12) and gear (17) on the shaft assembly. Install retainer (14) and bolt (15) on the shaft.12. Use tooling (B) to install lip-type seal (8) in housing (7). Install seal with the lip toward the inside of the housing. Put a small amount of clean engine oil on the lip of the seal.13. Install a new O-ring seal (18) on the housing.14. Put gear and shaft assembly (17) in position in the housing. Install bolts (16) that hold retainer (12) to the housing.
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face