Early models 1.6 L (AHL petrol engine)
Withdrawal
1. Disconnect the negative cable from the battery, drain the coolant as described in chapter 1A.
2. Move the front body panel to the service position - see chapter 11.
3. Remove the drive accessory belt as described in chapter 2A.
4. Remove the viscous fan coupling as described in paragraph 5.
5. As described in "Timing belt - removal, inspection and installation", remove the timing belt from the camshaft sprockets and water pump. There is no need to remove the belt from the crankshaft sprocket - the crankshaft pulley and the lower belt cover can become in place.
6. Loosen the screws and remove the upper part of the rear timing belt cover.
7. Turn away bots of fastening of the water pump. Remove the pump from the cylinder block and remove the O-ring (pic. 7.7).
Installation
8. First, thoroughly clean the pump seat in the block, removing all traces of the old sealant.
9. Obtain a new O-ring and moisten it with the prescribed type of antifreeze (see Recommended Fluids, Oils and Lubricants). Set the ring in its place in the block.
10. Install the pump in the block with the mounting lug down.
11. Screw in the fastening bolts and tighten them gradually and evenly to the prescribed torque.
12. Install the rear timing belt cover. Install timing belt - see chapter 2A.
13. Install viscous coupling with fan.
14. Install the front body panel as described in chapter 11 and tighten its fastening bolts to the specified torque.
15. Finally, fill in the coolant as described in the relevant part chapter 1 and connect the battery.
All other petrol engines (except AHL)
Withdrawal
16. Disconnect "mass" cable from the battery and drain the coolant as described in chapter 1A.
17. Move the front body panel to the position "maintenance", as described in chapter 11.
18. Remove the accessory drive belt as described in chapter 2A. On engines with air conditioning, the compressor drive belt does not need to be removed.
19. Remove the viscous fan coupling as described in paragraph 5.
20. Fix the power steering pump pulley by inserting a screwdriver into the pulley hole and resting it on the pump mounting bracket. Remove the outer section of the water pump pulley and remove the V-belt.
21. Loosen the clamps and disconnect the cooling system hoses from the back of the pump housing and thermostat housing.
22. Remove the alternator as described in chapter 5A.
23. Remove the power steering pump from its mounting bracket, as described in chapter 10. It is not necessary to remove the hydraulic pipes/hoses from the pump. Take the pump away from the bracket and tie it up so that it does not interfere.
24. Remove bolts/nuts (what is established) and remove the alternator and/or power steering pump brackets from the engine to gain access to the water pump housing.
25. Remove the bolts/studs securing the pump/thermostat housing to the block and remove the housing assembly from the motor.
Note: Some engines will require a bolt to be removed (s) fastening the timing belt cover to the housing assembly (see chapter 2).
Remove the o-ring installed between the housing and the block and discard it; installation requires new (Figure 7.25, a-c).
26. Having installed the assembly on the workbench, unscrew the mounting bolts and remove the pump from the housing (pic. 7.26). Discard the gasket - a new one is required for installation. The pump cannot be repaired, a faulty pump is always replaced. Remember to install the sawn head bolt.
Installation
27. Make sure the mating surfaces are clean. Attach a new gasket to the housing.
28. Mount the pump on the casing and evenly tighten the pump mounting bolts to the prescribed torque. Install the sawn head bolt, which also secures the timing belt cover, before bolting the pump to the engine.
29. Install a new O-ring into the housing groove and install the housing into the cylinder block. Install the mounting studs/bolts and tighten them to the specified torque.
30. Carefully attach the cooling system hoses to the body and securely tighten the clamps.
31. Install the bracket (s) alternator/power steering pump and tighten bolts/nut to specified torque.
32. Assemble the two halves of the water pump pulley and lay the V-belt on it. Fasten the pulley with the belt on the pump, tighten the fastening bolts and tighten them to the prescribed torque, turning the pulley by hand so as not to pinch the belt.
33. Install the power steering pump on the mounting bracket, as described in chapter 10.
34. Install the generator as described in chapter 5A.
35. Install the main accessory belt as described in chapter 2A.
36. Install the visco coupling with fan as described in paragraph 5.
37. Install the front body panel as described in chapter 11.
38. Finally, fill in the coolant as described in the relevant part chapter 1 and connect the generator.
Diesel engines
Withdrawal
39. Disconnect "mass" battery cable and drain the coolant. as described in chapter 1B.
40. Move the front panel of the body to the position "maintenance".
41. Remove main accessory drive frame - see chapter 2B. On medals with air conditioning, the compressor drive belt must be removed.
42. Remove the viscous fan coupling as described in paragraph 5.
43. Block the water pump pulley with an oil filter removal tool and remove the pulley from the water pump.
44. Turn away bolts of fastening of the water pump. Carefully remove the pump from the block and remove the O-ring (pic. 7.44).
Pic. 7.44. Details of fastening of the pump of the cooling system - diesel engines: 1. Pulley hub; 2. Bolt; 3. Bolt; 4. Cooling pump; 5. O-ring; 6. O-ring; 7. Housing; 8. Thermostat; 9. O-ring; 10. Bolt; 11. Thermostat housing cover
Installation
45. Make sure the mating surfaces of the pump and block are clean, install a new o-ring on the pump.
46. Wrap the pump mounting bolts and gradually and evenly tighten them to the prescribed torque.
47. Install the main auxiliary drive belt as described in chapter 2B.
48. Install a viscous coupling with a fan. as described in paragraph 5.
49. Install the front body panel as described in chapter 11.
50. Finally, fill the system with coolant as described in the relevant part chapter 1 and connect the battery.
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