Suzuki DF4 Water Pump Impeller Replacement

Tools Needed

• 10 mm wrench or socket
• 12 mm wrench or socket
• Screwdriver
• Razor blade

Safety

• Ensure the engine is in neutral before starting any work.
• Be careful when handling the drive shaft to prevent damage.

Steps

1. Remove the rubber cover to access the shift rod linkage.
2. Undo the shift rod linkage and the two bolts underneath to withdraw the lower unit with the drive shaft.
3. With the engine in neutral, use a 10 mm wrench to loosen the bolts that secure the gearbox.
4. Use a 12 mm wrench to remove the two bolts underneath the gearbox.
5. Tilt the engine up to access and remove the drive shaft.
6. Mount the gearbox in a workbench.
7. Remove the four 10 mm nuts or bolts securing the impeller housing.
8. Lift off the impeller housing carefully, ensuring the key and impeller do not fall out.
9. Inspect and replace the impeller and other water pump components as needed.
10. Clean the mating surfaces and apply new gaskets.
11. Reassemble the impeller housing, ensuring proper orientation of the holes and gaskets.
12. Reinstall the gearbox, ensuring the drive shaft is properly aligned.
13. Tighten all bolts to the manufacturer's specifications.

Tips

• Take pictures of the orientation of parts before disassembly to aid in reassembly.
• Be cautious not to move the spline position to avoid realignment issues.