Timing Belt /Water pump replacement on my 99 Epic (Continued)

[DRHRSH]

Next remove the alternator.  It is held by one bolt and one nut.  Let it hang out of the way.


Now remove the "lake" water pump assembly. There are several bolts that fasten it. One needs to be accessed through a hole in the pulley. Let it hang out of the way.



Then remove the center grooved idler pulley.


Now remove the center housing assembly with a smooth idler pulley.



Next remove the housing with another smooth pulley and the word "Toyota" on it.


At this point I decided I had to remove the ski pylon.  I used a pipe wrench and inside the engine compartment there is a 24mm bolt that needs to be loosened.  My 15/16" open end wrench fit it.  There are 2 19mm nut that need to be loosened to allow the pylon to pull up and out.


Now I could get my impact on the 22mm bolt.  It removed easily and the crank remained at TDC.


Here is where I used my steering wheel puller with the 2 M8x1.25x60mm bolts to attach it to the pulley.  Mine came off easily.


Now you can remove the small crankshaft housing cover.  Under it is a timing sprocket for the crankshaft sensor.  Make sure you don't forget to put this back on during reassembly!



This is what the crankshaft gear looks like.  The "official" timing marks are the small pimple on the housing and the index tab for the crankshaft pulley.  They are to the right of center.  I put my own green marks on the gear and housing.


These are the timing marks on the left (as viewed from the front)camshaft gear.  It is marked "R" because they consider it the right side..Hope this doesn't confuse. I enhanced the marks with a green sharpie.  The marks are similar on the other cam gear.


Next remove the 2 12mm bolts that hold the tensioner.  This slackens the timing belt so that you can remove it.


Now remove the bolts and studs that secure the water pump.  It may take some "love" and prying to free it.


Remove the water pump gasket and the O-ring on the tube near the top.



Clean up the gasket surface and set the new gasket and O-ring to place.  Put a small amount of grease on the O-ring to insure good seating of the new water pump.



Install the new water pump.

[elgringo-inaz]

OK, This is one awesome post by DRHRSH!  Thanks! 

Here is the deal:

99 Epic 22 with 870 hours.  At the lake yesterday and she started beeping while idleing.  I was on back deck getting ready to wakeboard and saw steam coming out exhast where deck meets boat, then she started to beep and wife looked at me like, uh, what is that?  Killed motor and got a tow back to marina.  An hour later restarted to put boat on trailer, no issue. 

I lifted engine cowel on the water at the time and noticed slight burt rubber or plastic smell.  I imagined impellar roasting?? Also, I felt a couple water hoses and they seemed empty.  So do I start with impellar, thermostat, or waterpump (hope not)....

Funny thing is I looked to temp gauge and of course it is on 160...stuck there! 

[tealmobileE22]

Hi elgringo-Inaz,
Last summer on my 1999 Epic 22, I changed out the impeller but I didn't do all of the tasks and pictures shown here.  This is very detailed for a water pump swap out too.  But it is always smart to change your impeller at least once every two years and once a season if you ride a lot of hours, I know some people blog that they change it with their oil once a season.  My boat only has just about 120 hours and the impeller was shredded and based on how the seals felt when taking it out, it was probably the first time it had been done on my boat.  If your boat has 870 on the hour gauge please do the right thing and start with the impeller and based on how it looks when you replace it go from there.  How to fix it is on the maintenance section. Good luck.

tealmobile22

[Wet-N-Frugal]

These are not necessarily the root issues, but worth checking on a boat with almost 900 hours.
* A leaky Tranny cooler causes premature impeller death. For a drip leak in the cooler allows seawater pump to bleed dry between uses.
* I would replace the exhaust hoses if not done already. These hoses fail from the inside out... they delaminate inside causing restricted flow. see post: http://www.epicmarine.com/forum4/index.php?topic=2089.msg16746#msg16746

-Good luck.

[CherokeeEpic22]

Thanks for taking the time to make the step by step pictures and directions i follow your directions had no issues Great job