Series 60

Section 4.3 Water Pump (Front Mounted) (Fm)

Section 4.3
Water Pump (Front Mounted) (Fm)

The centrifugal-type water pump circulates the engine coolant through the cylinder block, cylinder head, radiator and the oil cooler. See Figure "Front Mounted Water Pump " .‪

The pump is mounted on the front of the engine gear case cover on units built prior to 6R037024 and is driven by the water pump drive gear. The water pump drive gear meshes with the bull gear.‪

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Figure 1. Front Mounted Water Pump

An impeller is pressed on one end of the stainless steel drive shaft. The other end of this shaft has internal threads, and a retaining bolt secures the water pump drive gear to the shaft. Two identical roller bearing assemblies are used to carry the shaft See Figure "Front Mounted Water Pump Details and Relative Location of Parts " .‪

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 1. Locknut‪

12. Drive Shaft‪

 2. Gear, Water Pump Drive‪

13. Water Seal‪

 3. Snap Ring‪

14. Impeller‪

 4. Bearing Race‪

15. Seal Ring, Water Pump Cover‪

 5. Roller Bearing, Larger‪

16. Bolt, Cover-to-housing‪

 6. Spacer Rings (2)‪

17. Water Pump Cover‪

 7. Roller Bearing, Small‪

18. Bolt, Pump Housing to Gear Case Cover‪

 8. Bearing Race‪

19. Woodruff Key‪

 9. Oil Seal‪

20. Small Pipe Plug, Water Pump Housing‪

10. Seal Ring, Water Pump Housing‪

21. Large Pipe Plug, Water Pump Housing‪

11. Housing, Water Pump‪

22. Drain Cock‪

Figure 2. Front Mounted Water Pump Details and Relative Location of Parts

A rectangular rubber ring, located in a groove in the water pump housing, seals the water pump to the gear case cover. A smaller rectangular rubber ring, located in a groove in the water pump cover, seals the cover to the water pump housing. Engines built before October, 1989, are equipped with rubber O-ring seals on the water pump housing and cover. See Figure "Front Mounted Water Pump Details and Relative Location of Parts " .‪

An oil seal is located behind the bearing assemblies, and a unitized, spring-loaded, face-type water seal is used behind the impeller. This seal prevents water from leaking down the shaft and into the gear case. It also prevents lubricating oil from entering the cooling system. The water and oil seals cannot be replaced without removing the water pump from the engine.‪

The pump bearings are lubricated by splash oil through a passage from the front of the pump housing.‪

Section 4.3.1
Repair or Replacement of Water Pump (FM)

To determine if repair or replacement of the water pump is necessary, perform the following procedure. See Figure "Flowchart for Repair or Replacement of Water Pump (FM)" .‪

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Figure 3. Flowchart for Repair or Replacement of Water Pump (FM)

Section 4.3.2
Draining and Removal of Front Mounted Water Pump

Drain the cooling system as follows:‪

Open the drain cocks located at the right rear corner of the engine, at the bottom of the water pump and in the bottom of the thermostat housing.‪

Remove the water pump as follows:‪

  1. Loosen the hose clamps and remove the coolant hoses from the water pump housing.
  2. Loosen and remove the three water pump housing-to-gear case bolts. Remove the water pump from the engine by pulling it straight out of the gear case.

Section 4.3.3
Disassembly of Front Mounted Water Pump

Disassemble the water pump as follows:‪

  1. Loosen and remove the two water pump cover-to-pump housing bolts. Remove the water pump cover by pulling it straight out of the water pump housing, to prevent possible damage to the seal ring.

    NOTICE:

    If a vise is used to secure the water pump drive gear for locknut or impeller removal, use soft jaws on the vise and exercise extreme caution to prevent damage to the water pump drive gear teeth.‪

  2. Clamp the water pump drive gear in a vise, with the impeller facing up. Use a two-screw puller and remove the water pump impeller from the shaft, using the two threaded holes in the face of the impeller.
  3. Place the water pump face down on a press bed. Using J–35988–5A (part of tool set J–35988–C) and two breaker bars, loosen the locknut that secures the water pump drive gear to the shaft. Remove the locknut. See Figure "Water Pump Drive Gear Locknut Removal (FM)" .
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    Figure 4. Water Pump Drive Gear Locknut Removal (FM)

  4. Use a two-jaw puller to remove the water pump drive gear from the drive shaft.

    Note: Use care not to lose the Woodruff key.

    warning

    EYE INJURY

    To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).‪

  5. Remove the snap ring from the water pump housing. See Figure "Snap Ring Removal (FM)" .
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    Figure 5. Snap Ring Removal (FM)

  6. Support the water pump housing, engine side down, using steel blocks or plates; allow at least 76 mm (3 in.) of clearance between the pump housing and the press bed.
  7. Press the drive shaft and bearings assembly out through the back (engine side) of the water pump housing, until both bearing races are clear of the housing.

    NOTICE:

    Use care not to damage the housing. A damaged housing bore will cause coolant leaks and damage to the engine.‪

  8. Remove both the water and oil seals from the housing using a brass drift and hammer.
  9. Support the drive shaft assembly on two steel blocks, at the bearing inner race. See Figure "Removing Bearing Assemblies (FM)" .
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    Figure 6. Removing Bearing Assemblies (FM)

  10. Press the drive shaft out until it is clear of both bearing and race assemblies. Discard the used bearings, races and the two spacer rings located between the bearing packs.
Section 4.3.3.1
Inspection of Front Mounted Water Pump

Inspect the water pump parts as follows:‪

  1. Visually inspect the parts for cracks, wear or other damage.
    1. If parts are cracked, worn or have other damage, replace damaged or worn parts. Refer to "4.3.5 Assembly of Front Mounted Water Pump" .
    2. If parts are not cracked, worn or damaged, reuse remaining components.
  2. Inspect the water pump housing for relief slots in the water seal cavity. If the pump is without the relief slots, modify the area in which the impeller rides to add the slots. See Figure "Water Pump Body Modification (FM)" .

    Note: The gear case cover mount water pumps have two cast slots in the water seal cavity. Effective with Engine Serial Number 6R2807 machined relief slots were added to the pump. The relief slots ensure coolant flow to the seal faces.

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    Figure 7. Water Pump Body Modification (FM)

    NOTICE:

    If a vise is used to secure the water pump drive gear for locknut or impeller removal, use soft jaws on the vise and exercise extreme caution to prevent damage to the water pump drive gear teeth.‪

    1. Lock the water pump body securely in the soft jaws of a bench vise.
    2. Using a die grinder (if possible, have professionally machined), remove 38.1 mm (1.5 in.) of material in the 10 o'clock and 4 o'clock positions of the raised belt that surrounds the water pump impeller. See Figure "Water Pump Body Modification (FM)" . Enough material should be removed so that, when machined, the slot is flush with the rest of the casting.
    3. After machining, wash the pump housing and all other pump parts in clean fuel oil.
    4. warning

      EYE INJURY

      To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

    5. Dry with compressed air.

Section 4.3.4
Cleaning of Front Mounted Water Pump

Clean the water pump parts as follows:‪

  1. Wash all of the pump parts in clean fuel oil.
    warning

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

  2. Dry the parts with compressed air.

Section 4.3.5
Assembly of Front Mounted Water Pump

Assemble the water pump as follows:‪

  1. Coat the bearing bores of the water pump housing and the drive shaft bearing surfaces with clean engine oil.

    NOTICE:

    Although the bearings are identical, the bearings and races are matched parts, and should be installed as they are removed from the box. Parts that are not matched will cause damage to the water pump.‪

  2. Assemble new bearing packs. See Figure "Bearing Pack Assembly (FM)" .
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    Figure 8. Bearing Pack Assembly (FM)

  3. Install the drive shaft into the center of the fixture using J–35988–18 and J–35988–2 (parts of tool set J–35988–C) . See Figure "Bearing Installation Set-Up (FM)" .
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    Figure 9. Bearing Installation Set-Up (FM)

  4. Install the assembled bearing packs to the drive shaft. See Figure "Bearing Placement (FM)" .
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    Figure 10. Bearing Placement (FM)

  5. Use J–35988–1 (part of tool set J–35988–C) to press the bearing pack onto the shaft until it contacts the shoulder of the shaft using. See Figure "Bearing Installation (FM)" .
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    Figure 11. Bearing Installation (FM)

  6. Remove the shaft and bearing assembly from the press.
Section 4.3.5.1
Test Bearing Assembly (FM)

Check bearing assembly as follows:‪

Turn bearings to ensure they turn freely. If bearings bind, disassemble water pump and replace bearing assembly. Refer to "4.3.3 Disassembly of Front Mounted Water Pump" . If bearings do not bind, reuse the part.‪

Section 4.3.6
Assembly of Water Pump (FM)

Continue assembling the water pump, as follows:‪

  1. Coat the new oil seal contact area of the water pump housing with a thin film of clean engine oil. See Figure "Oil Seal Contact Area Lubrication (FM)" .
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    Figure 12. Oil Seal Contact Area Lubrication (FM)

  2. Install the oil seal to the water pump housing from the rear (gear side). See Figure "Oil Seal Positioning (FM)" .
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    Figure 13. Oil Seal Positioning (FM)

  3. Place the small end of J–35988–1 (part of tool set J–35988–C) into the water pump housing until it contacts the oil seal. See Figure "Oil Seal Installation (FM)" .
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    Figure 14. Oil Seal Installation (FM)

    NOTICE:

    The contact surface of the oil seal is coated with a special sealant. Do NOT remove this sealant before installing the oil seal. If sealant is removed, leakage can occur.‪

  4. Press the oil seal into the housing until the seal lip is bottomed in the pump housing. Remove J–35988–1 (part of tool set J–35988–C ).
  5. Coat the bearings with clean engine oil.
  6. Place the water pump housing, face down (gear side up), on a press bed.
  7. Install the drive shaft, with bearings installed, to the rear of the water pump housing. See Figure "Drive Shaft Insertion (FM)" .

    Note: During the bearing installation, the water pump housing must be parallel to the press bed or table surface.

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    Figure 15. Drive Shaft Insertion (FM)

  8. Place the large end of J–35988–1 (part of tool set J–35988–C) over the drive shaft so that the lip of the tool rests squarely on the outer bearing race. See Figure "Drive Shaft Installation (FM)" .
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    Figure 16. Drive Shaft Installation (FM)

    NOTICE:

    The drive shaft must be installed pressing on the outer bearing race only. Any other attempt at installation may damage the bearings.‪

  9. Press the drive shaft and bearing assembly into the water pump housing, using J–35988–1 (part of tool set J–35988–C) until it is seated firmly against the shoulder in the housing.
  10. Install the snap ring to the water pump housing. See Figure "Snap Ring Installation (FM)" .
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    Figure 17. Snap Ring Installation (FM)

    NOTICE:

    Form-a-Gasket Sealer must be used sparingly, and kept from the shaft and bearing surfaces. Excessive amounts of Form-a-Gasket Sealer could cause plugging of radiator or cooler core.‪

  11. Turn the water pump housing over. Working through the front, apply a coating of Aviation Form-a-Gasket, Form-a-Gasket No. 3 or equivalent to the area where the water pump seal case contacts the pump body. See Figure "Sealer Installation" .
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    Figure 18. Sealer Installation

  12. Install J–35988–3A (part of tool set J–35988–C) to the fixture tool. See Figure "Support Installation (FM)" .
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    Figure 19. Support Installation (FM)

  13. Install the water pump housing assembly to the fixture. See Figure "Water Pump Impeller Installation Set-Up (FM)" .
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    Figure 20. Water Pump Impeller Installation Set-Up (FM)

    NOTICE:

    The extension must contact and support the shaft when installing the water seal and impeller to prevent damage to the bearings.‪

  14. Turn the adjustor wheel to raise the extension until it contacts the drive shaft in the water pump housing.
  15. Apply Loctite® primer (Locquic Primer N, Part No. 764) by swabbing onto the I.D. of the rotor of the seal.
  16. Install a new water seal over the drive shaft and seat it in the water pump housing. See Figure "Water Seal Insertion (FM)" .
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    Figure 21. Water Seal Insertion (FM)

  17. Position J–35988–1 (part of tool set J–35988–C) over the water seal. See Figure "Water Seal Installation (FM)" .
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    Figure 22. Water Seal Installation (FM)

  18. Press the water seal into the housing until the flange of the seal case contacts the water pump housing a full 360°. Remove J–35988–19 (part of tool set J–35988–C) .
  19. With the water pump housing still housed in J–35988–2 (part of tool set J–35988–C) and located on a press bed, install the water pump impeller to the end of the drive shaft. Position the impeller so that the machined end is parallel with the housing machined face. See Figure "Water Pump Impeller Installation (FM)" .
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    Figure 23. Water Pump Impeller Installation (FM)

  20. Press the impeller on until it is flush with the end of the drive shaft. See Figure "Water Pump Impeller Location (FM)" .
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    Figure 24. Water Pump Impeller Location (FM)

  21. Turn the housing over and place it face (impeller side) down on J–35988–2, ( part of tool set J–35988–C) .
  22. Install the Woodruff key to its slot in the drive shaft. Tap the key with a brass hammer to seat it squarely in the slot. See Figure "Woodruff Key Installation (FM)" .
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    Figure 25. Woodruff Key Installation (FM)

  23. Install the water pump drive gear to the drive shaft, indexing the slot in the gear with the Woodruff key.

    NOTICE:

    Extension tool (J–35988–3A, part of tool set J–35988–C) must support the shaft. This is necessary to prevent damage to the bearings when pressing the gear onto the shaft.‪

  24. Turn the adjustor wheel to raise the extension tool (J–35988–3A, part of tool set J–35988–C) until it contacts the shaft.
  25. Using the small end of J–35988–1 (part of tool set J–35988–C) , press the drive gear down onto the drive shaft until it touches the bearings. See Figure "Water Pump Drive Gear Installation (FM)" .
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    Figure 26. Water Pump Drive Gear Installation (FM)

  26. Install locknut to the drive shaft threads. See Figure "Locknut Installation (FM)" .
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    Figure 27. Locknut Installation (FM)

  27. Using J–35988–5A (part of tool set J–35988–C) with a breaker bar to hold the gear and shaft, torque the locknut with a torque wrench to 203-230 N·m (150-170 lb·ft).
Section 4.3.6.1
Assembly Integrity Test

Verify the assembly integrity as follows:‪

  1. Turn the pump over and install J–35687 into the tapped holes provided in the impeller.
  2. Clamp J–35988–5A (part of tool set J–35988–C) (legs up) in a vise and position the lightening holes in the drive gear over the legs of the tool.
  3. Using a 1/2 in.-drive torque wrench in the hole provided in the center of J–35687 , apply 68 N·m (50 lb·ft) torque in either direction.
    1. The gear and impeller must withstand 68 N·m (50 lb·ft) torque without slipping.
    2. If the torque specification is not satisfied, disassemble water pump and replace the impeller. Refer to "4.3.3 Disassembly of Front Mounted Water Pump" .
  4. Using a dial indicator with a magnetic base, measure the total run-out of the water pump drive gear at four places, at 90 degree intervals. Maximum allowable run-out is 0.0635 mm (0.0025 in.). See Figure "Measuring Water Pump Drive Gear Runout (FM)" .
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    Figure 28. Measuring Water Pump Drive Gear Runout (FM)

    1. If specifications are exceeded, disassemble the water pump and check for burrs or foreign particles. Refer to "4.3.3 Disassembly of Front Mounted Water Pump" .
    2. If specifications are with limits, reuse part.

Section 4.3.7
Installation of Front Mounted Water Pump

Install the water pump as follows:‪

  1. Coat the two seal rings with clean engine oil. Install the larger seal ring to the groove in the water pump housing. Install the smaller seal ring to the groove in the water pump cover. Coat the water pump drive gear with clean engine oil.
  2. Install the water pump to the engine, meshing the water pump drive gear with the bull gear.
  3. Install the three water pump housing-to-gear case cover bolts. Tighten the bolts alternately and evenly to draw the water pump straight into the engine. Torque the bolts to 30-38 N·m (22-28 lb·ft).
  4. Measure the gear backlash. Refer to "1.24.2.1 Check Engine Timing" .
  5. Install the water pump cover to the water pump with two bolts. Torque the bolts alternately and evenly to draw the cover straight into the water pump housing. Torque the bolts to 30-38 N·m (22-28 lb·ft).
  6. Slide the coolant hoses into position and tighten the hose clamps.
  7. Fill the cooling system. Refer to "14.6.4 Cooling System" of preventive maintenance.


Series 60 Service Manual - 6SE483
Generated on 10-13-2008

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