30 Vellfire V6: Water Pump Replacement

Introduction

This is a water pump replacement for a 30 Vellfire.

It's a 2GR series V6 gasoline engine that uses D-4S.
Since it's just a water pump replacement, I thought it would be done in 2-3 hours!
But when I saw the actual vehicle, I was shocked.
It looks like a real pain to work on...

Checking the service manual, the water pump replacement is a job that assumes the engine is removed, with a standard labor time of 20 hours!

It makes sense why the customer was lamenting, 'The dealer told me it would cost 300,000 yen...'

That said, removing the engine is a hassle and I don't really want to do it, haha.
This time, I am replacing the water pump and thermostat without removing the engine by removing surrounding parts and adjusting the engine support.

To state the conclusion first, it was finished in 5-6 hours.

But! It was quite tough.

Start work from the front right side

First, lift the vehicle and remove the front right tire and undercovers. Check the area around the water pump and the workspace from the front right tire house side.

The water pump is located on the right side of the engine room, on the driver's side.

To create workspace from the hood side, loosen the air conditioner piping clamps, surrounding fixing parts, fuse box, etc., in order and move them as necessary.

Complaining won't get the job done, right?
I have to do it, but it's tough, isn't it? Haha.

Engine mount removal

I used a piece of wood as a shim and supported the bottom of the oil pan with a garage jack.
After making it possible to fine-tune the vertical position, I temporarily removed the engine mount on the driver's side.

When removing the mount, I almost got my hand caught between the engine and the subframe. That was dangerous!
I thought I was going to lose my fingers.

It is fixed with many bolts from above and below.
This is such a pain, isn't it!?

After the engine mount, remove the bracket.
It is fixed with a lot of bolts from above and from the side.

It's like a structure where brackets are layered on top of brackets.
I really think that if Suzuki were to make this, the number of parts would be much lower.

Water pump removal

After removing the engine mount and bracket, disconnect the two coolant pipes around the thermostat and one coupler.

The thermostat is secured at a total of four points: two nuts and two bolts. The water pump is secured by about 15 bolts, which vary in length and size.

It is easier to loosen the water pump pulley while the belt is still attached.

Remove all the pulley bolts, and once it can move freely, loosen the mounting bolts located under the pulley.

With this, you can remove the pulley and the water pump together.

After that, clean the mounting surface thoroughly and install in the reverse order to complete.

You should definitely manage the tightening torque for the water pump and thermostat properly!

Working time is about 5 to 6 hours.

Although the service manual lists this as a 20-hour job, I proceeded without removing the engine and finished in 5 to 6 hours in total.

Man, that was really tough. I could do it again if I were told to, but if you asked me if I would want to do it again by choice, I wouldn't (laughs).

After the work, I asked a mechanic who works at a dealership about the method, and they mentioned there is a technique where you remove both the left and right engine mounts and shift the engine toward the passenger side to create space.

I think, 'I see!', but since removing just the right mount was extremely difficult, I wonder if removing the left one would be quite a hassle in its own right. If I have the chance to do it again, I will try this method.

Summary

When searching for information, I see cases of similar water pump failures even in this model year of Vellfire.

Even if it's inevitable that it breaks, I wonder about the design when the official service manual states that you have to remove the engine to fix it.

If engine removal is expected, I wish they had designed it so that the engine could be removed easily.

I understand there are various reasons like how centralizing mass creates a sense of unity, but it's the mechanic who ends up crying during the work, and the customer who has to pay the labor costs.

Since they are customers who can afford a V6 Vellfire, they should be able to just pay 300,000 yen for the work without a second thought!
I mean, I can see that point of view, but still.

I took on this job thinking it would be done in about 3 hours since it's just a water pump replacement, and I've had a rough time, so if I ever take on the same job again, I'd like to charge a more proper amount (lol).

Alright then, see you later!