Water pump replacement

Welcome to 2CarPros.

This isn't an easy one to do because the timing belt needs removed. However, I will provide the directions first for belt removal (which needs done first) and then directions for water pump replacement. All attached pictures correlate with the directions. Also, if the belt has never been replaced, this is a good time to do it.

Here is a link that shows in general how one is replaced:

https://www.2carpros.com/articles/water-pump-replacement

Here are the directions specific to your vehicle.

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TIMING BELT

pic 1

COMPONENTS

NOTE: Please refer to Campaign Bulletin: KT2007070901 regarding Crankshaft Bolt Replacement.

REMOVAL
1. Using a [16 mm], rotate the tensioner arm clockwise (about 14°) and remove the belt from the pulley.
2. Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
3. Remove the upper and lower timing belt covers.

pic 2

4. Remove the auto tensioner.

pic 3

NOTE: Rotate the crankshaft clockwise and align the timing mark to set the No. 1 cylinder's piston to TDC (compression stroke). At this time, the timing marks of the camshaft sprocket and cylinder head cover should coincide with each other.

5. Unbolt the tensioner to remove the timing belt.

NOTE: If you plan to use the timing belt again, mark the rotation direction on the belt so you reinstall it correctly.

INSPECTION
1. Inspect the belt closely. If the following problems are evident, replace the belt with a new one.

pic 4

1) Hardened back surface of rubber Back surface is shiny, non-elastic and so hard that when the nail of your finger is pressed into it, no mark is produced.

pic 5

2) Cracked back surface of rubber.

pic 6

3) Side of belt is badly worn.

NOTE: A belt in good condition should have clear-cut sides as if it were cut with a sharp knife.

4) Teeth are badly worn out.
Initial stage: Canvas on load side of the tooth flank worn (fluffy canvas fibers, rubber gone, color changed to white, and unclear canvas texture)
Last stage: Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width reduced).

pic 7

5) Missing tooth

pic 8

2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner and idler pulley.

pic 9

TIMING BELT

INSTALLATION
The method of installing timing belt and auto tensioner.

pic 10

1. Install idler pulley to idler bracket.

pic 11

2. Install tensioner arm, shaft and plane washer to cylinder block.
Tightening torque: 35 - 55 Nm (350 - 550 kg-cm, 25 - 40 ft. lbs.)

pic 12

3. Install crankshaft sprocket and align the timing mark.

pic 13

CAUTION: Be careful not to bend crankshaft sensing blade.

pic 14

4. Install camshaft sprocket and adjust initial installation state as illustration.

pic 15

5. Install auto tensioner to oil pump case.

NOTE: At this time auto tensioner's set pin should be assembled completely.

pic 16

6. Align the timing marks of each sprocket and install the timing belt in this order. Crankshaft sprocket --> Idler pulley --> Exhaust camshaft sprocket (LH) --> Intake camshaft sprocket (LH) --> Water pump pulley --> Intake camshaft sprocket (RH) --> Exhaust camshaft sprocket (RH) Tensioner pulley

pic 17

NOTE:
- In this step, No. 1 is in TDC (Compression stroke)
- Do not insert fingers.

7. After installing the timing belt, reconfirm the timing mark.
8. Install the power steering pump pulley, idler puley and tensioner pulley.
9. Install the crankshaft pulley.
Tightening torque: 176 Nm (1800 kg.cm, 130 ft. lbs.)

CAUTION:
- Crankshaft bolt is a "one-time" use and must be replaced whenever it is removed.
- Include proper crankshaft bolt torque specs.

10. Pull out the auto tensioner set pin after adjusting timing belt tension. See: Timing Belt Tensioner > Adjustments

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water pump
12

2004 Kia Truck Sorento V6-3.5L

ENGINE COOLANT PUMP

pic 18

COMPONENTS

REMOVAL
1. Using the drain plug, drain the coolant.
2. Remove the drive belt and the engine coolant pump pulley.
3. Remove the timing belt cover, the auto tensioner and idler pulley.
4. Remove the water outlet fitting, the thermostat case and the water pump fitting.
5. Remove the engine coolant pump mounting bolts.

pic 19

6. Remove the engine coolant pump assembly from the cylinder block.

INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation and replace the pump assembly if necessary.
3. Check the seal it for leaks and replace the pump assembly if necessary.

INSTALLATION

pic 20

1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.

pic 21

2. Install the new engine coolant pump gasket and pump assembly. Tighten the bolts to the specified torque.
Tightening torque
Engine coolant pump bolt:
Head mark "7": 17 - 22 Nm (170 - 220 kg-cm, 12 - 16 ft. lbs.)
3. Install the water pump fitting, the thermostat case and the water outlet fitting.
4. Install the auto tensioner and timing belt. Adjust the timing belt tension, then install the timing belt cover.
5. Install the drive belt, coolant pump pulley and then adjust the auto tensioner.
6. Refill the coolant.
7. Run the engine and check for leaks.

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Let me know if this helps or if you have other questions.

Take care,
Joe

Welcome back:

Yes, that all needs removed.

4. Remove the water outlet fitting, the thermostat case and the water pump fitting.

Let me know if I can help.

Joe