2002 Suzuki vz800 im trying to remove the water pump case I've take out both bolts and the hoses. I have a new one ready to install but I can't take off the water pump case is there something holding it on from the inside or ? Please help I'm at standstill

Hello. Here a non-photo diagram. Hope this helps!!!

The thermostat is located on the side of the water pump, the water pump is located just above the a/c compressor, the thermostat is fed coolant from the radiators lower radiator hose.
Thermostat :
1. drain coolant and tighten drain plug ( easier method : remove radiator cap, get big drain pan, place drain pan under lower radiator hose to radiator connection, remove clamp, slowly remove hose, allow coolant to drain into pan, now is a good time to remove radiator hose and clamp from thermostat housing )
2. remove thermostat cover / cap ( easiest to get at this when front of car is supported by jack stands and right hand side lower cover is removed ).
3. thermostat cap is held on by 3 bolts / remove thermostat.

You will notice that the thermostat's air bleed hole is pointing up and lines up with notch in water pump housing,,

ATTENTION :failure to install new thermostat in the correct location will cause engine to overheat.

1. install new thermostat to water pump, make sure air bleed hole lines up with notch, install and tighten bolts, install a new lower radiator hose, fill cooling system.

thermostat # 17670-77E00
lower radiator hose #17854-65G20
hose clamp #09401-36403
upper radiator hose # 17852-65G20

Suzuki factory manual

3.9L, 4.7L, 5.2L, 5.9L, 8.0L Gasoline Engines

1. Carry out the "Common Steps" above.
2. Remove the upper radiator hose.
3. Remove the fan and shroud assembly.
4. On engines except 4.7L, remove the four water pump pulley bolts and remove the pulley.
5. Remove the heater hose pipe mounting bolt, if fitted.
6. On engines except 4.7L, loosen the bypass hose clamp at the water pump.
7. Remove the seven water pump mounting bolts and, on the 4.7L, one nut.

WARNING Bolts may be of different lengths. Be sure to note their locations.
To install:

1. Reverse the removal procedure.
2. The 8.0L engine uses an O-ring to seal. Use a new one and lubricate it with petroleum jelly before installation of the pump. Also, use sealant on the threads of the heater hose pipe, position the pipe as shown before installing the pump and tighten the nut to 12 ft. lbs. (16 Nm).
3. On pushrod engines, connect the bypass hose to the pump while installing it.
4. Tighten the bolts to 30 ft. lbs. (40 Nm) on pushrod engines, 40 ft. lbs. (54 Nm) on the 4.7L engine.
5. Spin pump to ensure the impeller is not rubbing against the timing chain case.
6. When installing the heater hose pipe, ensure that the slot in the pipe bracket is bearing against the mounting bolt. This will hold the pipe in as far as possible to prevent leaks.
7. Tighten pulley bolts to 20 ft. lbs. (27 Nm) on V-6 and V-8, 16 ft. lbs. (22 Nm) on the V-10.

Fig. Water pump bolts differ in length; note check location before installation-3.9L, 5.2L, and 5.9L gasoline engine shown

Hope helps (remember to rate this answer).

Thermostat Removal & Installation 4.8L, 5.3L and 6.0L Engines To Remove:
CAUTION
The thermostat is not serviceable separately. The thermostat housing (water pump inlet) and thermostat must be replaced as an assembly.

1. Remove the radiator outlet hose.
   
   
2. Remove the bolts from water pump inlet.
3. Remove the water pump inlet from the water pump.

To Install:

1. Install the water pump inlet to the water pump.
2. Install the water pump inlet bolts. Torque to: 11 ft-lbs. (15 Nm)
3. Install the radiator outlet hose.

8.1L Engines To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Drain the cooling system.
3. Remove or disconnect the following:
   • Inlet hose from the water outlet Water outlet and thermostat removal
     
     
   • Water outlet bolts (B)
   • Water outlet (A)
   • Thermostat (C)

To Install:

1. Install or connect the following:
   • Thermostat
   • Water outlet
   • Water outlet bolts and tighten the bolts, Torque to: 22 ft-lbs (30 Nm)
   • Inlet hose to the water outlet
2. Fill the cooling system.
3. Test drive the vehicle to confirm the repairs.

REMOVAL & INSTALLATION
2.0L Engine

1. Disconnect the negative battery cable.

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

1. Drain the engine cooling system.
2. Raise and safely support the vehicle.
3. Remove the lower radiator hose from the water pump.

If the lower radiator hose is hard to reach on the back of the water pump, remove the hose at the radiator and after the water pump is ready to be removed, pull the water pump away from the engine block until there is enough room to remove the hose from the pump.

1. Lower the vehicle.
2. Remove the accessory drive belt.
3. Remove the timing belt covers and the timing belt as outlined in this Section.
4. Remove the four water pump retaining bolts.
5. Remove the water pump.
   

To install:

1. Thoroughly clean all sealing surfaces.
2. Install a new water pump gasket and the water pump onto the cylinder block.
3. Tighten the retaining bolts to 12-15 ft. lbs. (16-20 Nm).
4. Reinstall the timing belt and the timing belt covers as outlined in this Section.
5. Reinstall the accessory drive belt.
6. Raise and safely support the vehicle.
7. Reinstall the lower radiator hose.
8. Lower the vehicle.
9. Fill the engine cooling system.
10. Reconnect the negative battery cable.
11. Start the engine and top off the coolant as necessary. Check for leaks.

2.5L Engine

Before continuing with this procedure, be sure three new water pump retaining bolts (W701544) are available. Due to their torque-to-yield design, the bolts stretch and cannot be reused.

1. Disconnect the negative battery cable.

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

1. Drain the engine cooling system.
2. Remove the water pump pulley shield.
3. Remove the water pump drive belt.
4. Remove the water pump inlet and outlet hoses from the water pump.
5. Remove the three water pump to left cylinder head retaining bolts.
6. Remove the water pump and water pump housing from the vehicle.
7. Remove the water pump to water pump housing retaining bolts and separate the water pump from the water pump housing.

To install:

1. Thoroughly clean all sealing surfaces.
2. Install the water pump to the water pump housing using a new gasket and install the retaining bolts. Tighten the retaining bolts to 16-18 ft. lbs. (22-25 Nm).
3. Position the water pump and water pump housing and install three new torque-to-yield retaining bolts into the left cylinder head.
4. Tighten the new retaining bolts to 11-13 ft. lbs. (15-18 Nm), then rotate the retaining bolts 85-95 degrees.
5. Reinstall the water pump inlet and outlet hoses to the water pump.
6. Reinstall the water pump drive belt.
7. Reinstall the water pump shield.
8. Fill the engine cooling system.
9. Reconnect the negative battery cable.
10. Start the engine and top off the coolant as necessary. Check for leaks.

Hope helps (remember comment and rated this).

Hope this helps!

Common Steps

1. Disconnect the battery negative cable(s).
   
2. Drain the cooling system.
   
3. Remove the accessory drive belt.
   
4. Remove the lower radiator hose (except Diesel).
   
5. Disconnect the heater hose from the pump, if fitted.
   

WARNING Most cooling system hoses use "constant tension" hose clamps. When removing or installing, use a tool designed for servicing this type of clamp. The clamps are stamped with a letter or number on the tongue. If replacement is necessary, use only an OEM clamp with a matching ID.




Heater hose pipe O-ring (arrow): twist gently when removing or installing; check condition; lubricate with coolant before installing

CAUTION Always wear safety glasses when servicing contact tension clamps.

1. Always use a new gasket when installing the water pump. Clean mating surfaces thoroughly before installation.
   
2. This would be a good time to replace radiator hoses. At least, inspect them carefully for aging or other damage.
   
3. If the heater hose pipe was removed, use thread sealant or equivalent on the pipe threads (if threaded), or lubricate any O-rings with coolant before installing.
   
4. Check the accessory belt routing against the plate in the engine compartment before starting engine.
   
5. Allow the engine to reach operating temperature and check for leaks.
   

3.9L, 4.7L, 5.2L, 5.9L, 8.0L Gasoline Engines

1. Carry out the "Common Steps" above.
   
2. Remove the upper radiator hose.
   
3. Remove the fan and shroud assembly.
   
4. On engines except 4.7L, remove the four water pump pulley bolts and remove the pulley.
   
5. Remove the heater hose pipe mounting bolt, if fitted.
   
6. On engines except 4.7L, loosen the bypass hose clamp at the water pump.
   
7. Remove the seven water pump mounting bolts and, on the 4.7L, one nut.
   

WARNING Bolts may be of different lengths. Be sure to note their locations.


To install:

1. Reverse the removal procedure.
   
2. The 8.0L engine uses an O-ring to seal. Use a new one and lubricate it with petroleum jelly before installation of the pump. Also, use sealant on the threads of the heater hose pipe, position the pipe as shown before installing the pump and tighten the nut to 12 ft. lbs. (16 Nm).
   
3. On pushrod engines, connect the bypass hose to the pump while installing it.
   
4. Tighten the bolts to 30 ft. lbs. (40 Nm) on pushrod engines, 40 ft. lbs. (54 Nm) on the 4.7L engine.
   
5. Spin pump to ensure the impeller is not rubbing against the timing chain case.
   
6. When installing the heater hose pipe, ensure that the slot in the pipe bracket is bearing against the mounting bolt. This will hold the pipe in as far as possible to prevent leaks.
   
7. Tighten pulley bolts to 20 ft. lbs. (27 Nm) on V-6 and V-8, 16 ft. lbs. (22 Nm) on the V-10.
   

Water pump mounting hardware—4.7L



Use a prybar to keep the water pump from rotating while pulley bolts are removed



Bypass hose clamp (arrow) must be tended to before removing the pump



Water pump bolts differ in length; note check location before installation—3.9L, 5.2L, and 5.9L gasoline engine shown



After removing the bolts, pull off the pump and place it in a safe location

The water pump can be removed and installed without discharging the air conditioning system (if equipped).

1. Disconnect battery negative cable.
2. Drain cooling system. Refer to Draining and Filling found under Cooling System, Service and Repair.
3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
4. Remove upper radiator hose clamp and hose at radiator.
5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
6. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive.
7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top).
8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit.
9. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.
10. Do not remove water pump pulley bolts at this time.
11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt.
12. 12. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle.
13. Remove lower radiator hose clamp and remove lower hose at water pump.
14. Remove heater hose clamp and heater hose from heater hose coolant return tube.
15. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring.
16. Remove seven water pump mounting bolts.
17. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.

INSTALLATION

1. Clean gasket mating surfaces.
2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque.
3. Position bypass hose clamp to bypass hose.
4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube.
7. Connect radiator lower hose to water pump.
8. Connect heater hose and hose clamp to coolant return tube.
9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating.
10. Relax tension from belt tensioner. Install accessory drive belt.
11. CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to Illustration above for correct belt routing. The correct belt with correct length must be used.
12. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit.
13. Install fan shroud.
14. Install fan blade/viscous fan drive assembly to water pump shaft.
15. Fill cooling system.
16. Connect battery negative cable.
17. Start and warm the engine. Check for leaks.

Removal & Installation 3.0L (2V) To Remove:

1. Drain the engine cooling system.
2. Loosen the water pump pulley.
3. Remove the bolt and the nut and position the roll restrictor bracket out of the way.
4. Remove the accessory drive belt.
5. Remove the generator.
6. Remove the bolt and the accessory drive belt tensioner.
7. Remove the nut, the bolt and the support bracket.
8. Remove the bolts and the water pump pulley.
9. Disconnect the water pump inlet hose and the crankshaft position sensor electrical connector.
10. Remove the bolts and the water pump, and clean the sealing surfaces

To Install:

1. Install the water pump. Tighten bolts in the sequence shown:
1. Tighten numbers 1-7 to 18 ft.-lbs. (25 Nm)
2. Tighten numbers 8-12 to 89 in.-lbs. (10 Nm)
3. Connect the crankshaft position sensor electrical connector and the water pump inlet hose
4. Install the support bracket.
5. Install the accessory drive shaft tensioner.
6. Install the generator.
7. Install the roll restrictor bracket, bolt and the nut.
8. Install the water pump pulley.
9. Install the accessory drive belt.
10. Connect the battery ground cable.
11. Fill the engine cooling system.

Water pump bolt torque sequence (3.0L (2V) engine)

1. Clean gasket mating surfaces.
2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts Tighten water pump mounting bolts to 40 N·m (30 ft. lbs.) torque.
3. Position bypass hose clamp to bypass hose.
4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
5. Install a new O-ring to the heater hose coolant return tube Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube.
7. Connect radiator lower hose to water pump.
8. Connect heater hose and hose clamp to coolant return tube.

If you have any questions feel free to ask. Let me know if you dont get diagrams(happens sometimes)

Reverse rotation water pump—2.5L and 4.0L engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this manual.
2. Drain the cooling system.
3. Remove or disconnect the following: NOTESome 4.0L engines are equipped with a fan clutch that threads Directly on to the water pump shaft. This fan clutch is equipped with right-hand threads. NOTEDo not store the fan clutch assembly horizontally, silicone may leak into the bearing grease and cause contamination. NOTEOne of the water pump bolts is longer than the others. Note the location for reassembly.
   • Negative battery cable
   • Electric cooling fan connector
   • Accessory drive belt
   • Engine cooling fan and pulley
   • Water pump pulley
   • Power steering pump
   • Lower radiator hose from the water pump
   • Heater hose
   • Water pump and discard the gasket

To install:

1. Clean the mating surfaces of all gasket material.
2. Install or connect the following:
   • Water pump using a new gasket. Torque the bolts to 17 ft. lbs. (23 Nm).
   • Heater hose
   • Lower radiator hose
   • Water pump pulley. Torque the bolts to 20 ft. lbs. (27 Nm).
   • Power steering pump
   • Engine cooling fan and shroud. Torque the bolts to 31 inch lbs. (3 Nm).
   • Accessory drive belt
   • Electric cooling fan connector
   • Negative battery cable
3. Fill and bleed the cooling system.
4. Start the engine, check for leaks and repair if necessary.

3.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this manual.
2. Drain the cooling system.
3. Remove or disconnect the following:
   • Negative battery cable
   • Fan and clutch assembly from the pump
   • Fan shroud and fan assembly. If you’re reusing the fan clutch, keep it upright to avoid silicone fluid loss!
   • Lower hose
   • Water pump (8 bolts)
4. Installation is the reverse of removal. Tighten the bolts, in sequence, to 40 ft. lbs. (54 Nm). Water pump tightening sequence—3.7L

follow the upper radiator hose to the housing on the intake manifold. it is held down with 2 bolts. on some small vehicles it will be located under throttle body hose from the air filter.please rate this.