Hyundai Repair: Water pump removal and install, timing belt tensioner, crankshaft pulley


Question
Hi,

I own a 96 accent. Water pump just gave out. COuld you please indicate the steps involved in the removal and installation of a new one. Any tips? It seems to be in a very awkward place. Thanks for any help you can send my way HT.  

Answer
You'll need to remove the timing and drive belts to do this job, so if you haven't replaced them recently, it may be in your best interest to pick them up and replace them while you're replacing the water pump.  You'll also want to replace the o-ring where the water pump attaches to the coolant pipe.

I've listed below the steps in replacing the water pump as best I can recall for the 1.5L engine.  I'd also recommend getting a free account at www.hmaservice.com (requires Internet Explorer) and looking at the procedure (very vague) and diagrams there.

1.  Drain the coolant.
2.  Remove the right side engine mount.
3.  Loosen the 4 water pump pulley bolts.
4.  Remove the drive belts.
5.  Remove the water pump pulley.
6.  Remove the crankshaft pulley.
7.  Remove the timing belt covers.
8.  Align the timing marks.
9.  Loosen the two 12mm bolts holding the timing belt tensioner pulley.
10.  Pry the pulley away from the timing belt and tighten the pulley clamping bolt to hold it in place.
11.  Remove the timing belt.
12.  Remove the timing belt tensioner and idler pulleys.
13.  Remove the water pump.
14.  Clean the old gasket off the engine completely.
15.  Replace the coolant pipe o-ring.
16.  Install the new water pump and gasket.
17.  Reinstall the timing belt idler pulley.  
18.  Reinstall the timing belt tensioner pulley, leaving the attaching bolts loose.  Be sure to pry the tensioner spring into place properly.
19.  Pry the tensioner pulley back and clamp it down with the bolt.
20.  Install the timing belt with all the slack on the tensioner side.
21.  Release the tensioner pulley to set itself and clamp back in place.
22.  Rotate the crankshaft 2 revolutions clockwise.
23.  Check your timing marks.  If incorrect, go back to step 19, realigning the timing marks before you reinstall the timing belt.
24.  Release the clamping bolt one more time to set the final tension.
25.  Tighten the tensioner clamping and pivot bolts.
26.  Reinstall the timing belt covers.
27.  Reinstall the crankshaft pulley.
28.  Reinstall the water pump pulleys.  Use a pair of pliers to hold the pulley while you tighten the bolts.
29.  Install the drive belts and tension.
30.  Reinstall the motor mount.
31.  Fill the radiator with a 50/50 coolant mixture.
32.  Start the car and run with radiator cap off, monitoring temperature, coolant level (topping as needed), and coolant flow.
33.  After the coolant fans have cycled at least two times, the air should be out of the system.  Top off as necessary.