Water Pump: Service and Repair

Special Tool:
- Press Tool No. 999 5456, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to Service and Repair.

Procedure





1. Drain coolant:
- Remove expansion tank cap.
- Raise car.
- Remove splashguard.
- Open engine and radiator nipples. Use hoses to collect coolant.
- Close nipples.





2. Remove:
- spark plug cover
- two fuel pipe clips
- lift up expansion tank and lay on engine
- front timing cover
- right front wheel
Undo wing liner to expose vibration damper.
Turn engine crankshaft to align timing marks.





3. Remove:
- upper timing cover
- Belt tensioner
Undo timing belt and put to one side.
Compress tensioner using tool 999 5456, or equivalent.





4. Remove water pump and clean gasket face and mating surfaces
- Carefully clean and scrape off gasket residues from cylinder block.





5. Install water pump:
- Use new gasket.
- Tighten screws to 20 Nm (14.8 ft lb).





6. Install:
- belt tensioner
- timing belt
- upper timing cover
Pull locking pin from belt tensioner.
Turn crankshaft two revolutions until timing marks line up.





7. Install:
- front timing cover
- expansion tank
- two fuel pipe clips
- spark plug cover
- splashguard under engine
Fill with coolant.
Run engine warm and top up if necessary.
Check for leaks.