Attention! Proceed with the procedure only after the engine has completely cooled down! See also the warnings at the beginning of the Section Antifreeze - general information.
Gasoline engine water pump installation details
Diesel engine water pump installation details
1 - Bypass hose; 2 - Spacer; 3 - Coolant supply pipe to the turbocharger; 4 - Water pump; 5 - Alternator adjusting bracket; 6 - Oil seal; 7 - Rear timing belt cover
1. Disconnect the negative cable from the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
Empty the cooling system (see chapter Vehicle settings and routine maintenance). If the coolant was recently changed, keep it for future reference (see warning in Section Antifreeze - general information).
2. Drain the coolant.
3. Remove the timing belt and intermediate roller No. 2 (see chapter Engine).
4. Remove the thermostat housing from the water pump assembly (see Section Check of serviceability of functioning and replacement of the thermostat).
5. On a gasoline engine, remove five bolts, two column bolts and a nut, and then separate the water pump assembly from the engine (refer to illustration above). A new gasket will be required during installation, so the removed gasket can be discarded.
6. On a diesel engine, remove the radiator fan and water pump pulley, remove the three bolts and remove the alternator adjusting bracket (refer to illustration above).
7. On a diesel engine, release two nuts and disconnect the coolant supply pipe to the turbocharger from the water pump and bypass hose. Then turn out five bolts and remove the water pump together with gasket
8. Thoroughly clean the mating surfaces, then wipe them with a clean cloth soaked in acetone.
9. Install a new O-ring on the end of the bypass tube and a new water pump gasket.
10. Further installation is carried out in the reverse order to the dismantling of the components. Make sure all fasteners are tightened to the correct torque.
11. Fill the cooling system (see chapter Vehicle settings and routine maintenance), start the engine and check it for signs of leak development.