Water pump - r + r with engine removed

Operation 1088C20 · Water pump and thermostat

1.6 TS

Removing

1. Adjust the automatic belt tensioner with a wrench to slacken the tension of the single drive belt.

2. Remove the single drive belt.

3. Undo the bolt (3a) and rmeove the fixed belt tensioner (3b) for the engine components single belt.

1. Undo the bolts (1a) and remove the upper timing belt guard (1b).

2. Loosen the timing belt tensioner nut.

3. Remove the timing belt from the camshaft drive pullies.

1. Undo the bolt (1a) and remove the left side timing belt guard (1b).

2. Undo the bolts (2a) on the inlet side camshaft pulley, using the tool (2b) for counter-torque.

3. Remove the inlet side camshaft pulley.

4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

Refitting

1. Fit the water pump (1a) complete with new O-ring (1b) and fix it tightening the bolts (1c) to the recommended torque.

2. Fit the inlet side camshaft pulley (2a) and fix it using the bolts (2b) without tightening them.

3. Fit the left side timing belt guard (3a) and fix it using the bolt (3b).

Loosen the bolt on the exhaust side camshaft pulley using the tools for counter-torque.

1. Disconnect the electrical connections from the ignition coils.

2. Disconnect the earth lead from the cylinder head.

3. Disconnect the high-tension leads (3a) from the spark plugs using the tool (3b).

Undo the bolts and remove the bracket complete with ignition coils and high-tension leads.

Undo the bolts and remove the rocker cover complete with gasket.

1.6 TS · 103 CV

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Undo the bolts an remove the third caps from the inlet and exhaust camshafts.

2. Fit the tool (2a) in place of the removed camshaft caps, and fix it tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile matches the tool perfectly.

1.6 TS · 120 CV

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Undo the bolts an remove the third caps from the inlet and exhaust camshafts.

2. Fit the tool (2a) in place of the removed camshaft caps, and fix it tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile matches the tool perfectly.

1.6 TS

Fit the timing belt.

1. Apply maximum tension to the timing belt using the tool.

2. Tighten the timing belt tensioner nut to the specified torque.

3. Tighten the bolts (3a) of the inlet side camshaft pulley, using the tool (3b) for counter-torque.

4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

1.6 TS · 103 CV

Undo the bolts and remove the tool.

1.6 TS · 120 CV

Undo the bolts and remove the tool.

1.6 TS

Fit the camshaft caps removed previously and tighten the bolts to torque.

Rotate the crankshaft through two revolutions.

Slacken the timing belt tensioner nut.

5. Line up the moving reference (5a) on the timing belt tensioner with the reference hole (5b) using the tool (5c).

Tighten the timing belt tensioner nut to the specified torque.

Remove the tool complete with dial gauge.

Fit the spark plug for cylinder no. 1.

Fit the rocker cover complete with gasket and fix it using the bolts.

Fit the bracket complete with ignition coils and high-tension cables and fix it using the bolts

Connect the high tension leads to the spark plugs.

Connect the earth lead to the cylinder head.

Connect the electrical connections to the ignition coils.

Fit the upper timing belt guard and fix it using the bolts.

Fit the fixed single drive belt tensioner and fix it with its bolt.

Fit the engine components single drive belt using a spanner in the automatic belt tensioner for leverage.

2.0 TS

Removing

1. Undo the bolts (1a) and the nut (1b) and remove the auxiliary units drive belt protection (1c).

2. Use a spanner on the moving tensioner (2a) and remove the single drive belt (2b).

3. Remove the cap (3a), undo the bolt and remove the single belt fixed tensioner (3b).

1. Undo the bolts (1a) and remove the upper timing gear cover (1b).

2. Undo the bolts (2a) and remove the auxiliary shaft drive pulley (2b).

3. Undo the bolts (3a) and remove the lower timing cover (3b).

4. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.

5. Release and remove the counter-balance shaft drive belt.

6. Slacken the nut on the timing belt moving tensioner.

7. Prise off and remove the timing belt.

1. Undo the bolts (1a) and remove the left side protective timing cover (1b).

2. Undo the bolts (2a) of the inlet side drive pulley, using the tool (2b) for counter-torque.

3. Remove the inlet side driven pulley.

4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

Refitting

1. Place water pump (1a), complete with a new O-ring (1b), back in its housing and fix it tightening the bolts (1c) to the recommended torque.

2. Fit the inlet side driven pulley (2a) and fix it using the bolts (2b) without tightening them.

3. Place the left side protective timing cover (3a) back in its housing and secure it using the bolts (3b).

4. Loosen the bolt (4a) for the exhaust side driven pulley using the tools (4b) and (4c) for counter-torque.

1. Disconnect the electrical connections from the ignition coils.

2. Undo the bolt (2a) and disconnect the earth lead (2b) from the ignition coils support plate.

3. Disconnect the covers for the high tension leads (3a) from the spark plugs using the tool (3b).

4. Disconnect the oil vapour recovery pipe from the rocker cover.

Undo the bolts fixing the ignition coil support plate.

Pull the plate, complete with ignition coils, upwards.

Undo the bolts and remove the rocker cover complete with gasket.

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

Rotate the crankshaft in a clockwise direction until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

If TDC is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at TDC.

Undo the bolts and remove the camshaft third cap.

2. Fit the tool (2a) in place of the camshaft caps removed and fix it tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

1. Fit the toothed timing belt following the order shown in the diagram:

toothed drive pulley (1a)

fixed tensioner (1b)

exhaust side toothed driven pulley (1c)

Before fitting the belt on the exhaust side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

intake side toothed driven pulley (1d)

Before fitting the belt on the inlet side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

mobile tensioner (1e)

coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation (clockwise - timing side).

1. Using the tool, rotate the timing moving tensioner until the maximum tension is applied to the timing belt.

2. Tighten the nut for the moving tensioner to the recommended torque.

1. Tighten the bolts (1a) for the camshaft driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

2. Tighten the bolt (2a) fixing the timing driven pulley to the recommended torque, using the tools (2b) and (2c) for counter-torque.

Remove the tool for timing the camshafts.

Place the previously removed camshaft caps back in their housings and secure them tightening the bolts to the recommended torque.

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) and ensure that the piston for cylinder no. 1 is at TDC.

1. Fit the tool (1a) for keeping the moving timing tensioner still and loosen the tensioner nut (1b).

2. Rotate the tool (2a) in an anti-clockwise direction (timing side) until the tensioner moving reference (2b) coincides with the reference opening (2c).

3. Tighten the nut for the moving tensioner to the recommended torque.

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) until cyllinder no. 1 is at TDC in the explosion stroke and check that the engine timing is correct using the tool.

Remove the tool to check T.D.C. from the cylinder 1 spark plug socket.

Place the spark plugs for cylinder no. 1 back in their housings and tighten them to the recommended torque.

1. Rotate the counter-balance shafts so that the references (1a) on the pullies are aligned with the ribs (1b).

2. Temporarily fit the lower timing cover and the crankshaft pulley and check the alignment of the references.

Fit the counter-balance shaft toothed drive belt.

1. Tension the counter-balance shaft drive belt using the tool (1a) so that the reference opening (1b) in the belt tensioner is at the centre of the rotation sector.

2. Tighten the nut fixing the counter-balance shaft drive belt tensioner to the recommended torque.

Place the tapper cover, complete with gasket, back in its housing and fix it using the bolts.

Connect the oil vapour recovery pipe to the rocker cover.

Fit the plate complete with ignition coils and high-tension cables and fix it using the bolts.

Connect the high-tension leads to the spark plugs.

Connect the earth lead to the ignition coils support plate.

Connect the electrical connections to the ignition coils and position the electrical wiring in its housing.

Fit the lower protective timing cover and secure using the bolts.

Place the timing belt upper cover back in its housing and secure it using the bolts.

Fit the engine components belt drive pulley and fix it tightening the bolts to torque.

Place the engine components single drive belt fixed tensioner back in its housing and fix it tightening the bolt to the recommended torque.

Place the plug back in its housing in the fixed tensioner.

Use a spanner on the moving tensioner and fit the engine components single drive belt.

Place the auxiliary units drive belt protection back in its housing and secure it using the bolts and the nut.

3.2 V6

Removing

Proceed with removal - 1004D40 engine - position on stand and remove.

1. Open the electrical connections box cover.

2. Disconnect the electrical connection for the detonation sensor, timing side.

1. Loosen the bands fixing the inlet ducts to the air chamber.

2. Loosen the band securing the engine oil vapour recovery pipe to the air chamber.

3. Disconnect the electrical connection from the throttle body integrated with the D.V.L.

1. Undo the fixing bolt (1a) and disconnect the earth lead (1b) from the air capacity chamber.

2. Undo the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.

3. Undo the bolts (3a) and remove the air chamber (3b).

1. Disconnect the electrical connections from the right cylinder head injectors.

2. Disconnect the electrical connections from the right cylinder head ignition coils.

3. Undo the bolts (3a) and move the electrical wiring (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head.

1. Undo nut (1a) and disconnect earth lead (1b) from the left cylinder head.

1. Undo the bolts (1a) and remove the left cylinder head ignition coils cover (1b).

1. Disconnect the electrical connections from the left cylinder head injectors.

2. Disconnect the electrical connections from the left cylinder head ignition coils.

3. Undo the bolts (3a) and move the electrical wiring (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head.

1. Undo the bolts (1a) and remove the upper protective timing cover (1b).

1. Undo the bolts (1a) and remove the lower protective timing covers (1b).

1. Loosen the bolts fixing the timing belt moving tensioner.

2. Release the timing drive belt from the driven pullies.

1. Undo the bolts (1a), the bolt (1b) and remove the bracket (1c).

1. Undo the bolts (1a) and remove the tappet cover for the left cylinder head (1b), complete with gasket.

1. Loosen the bolts (1a) fixing the driven pullies using the tool (1b) for counter-torque.

1. Undo the bolts (1a) and remove the right cylinder head tappet cover (1b), complete with gasket.

1. Undo the bolt (1a) and remove the fixed timing belt tensioner (1b).

2. Undo the fixing bolts (2a) and remove the water pump (2b) complete with cover (2c) and bracket (2d).

Whilst removing the water pump take care not to release the rigid water pump inlet pipe from the thermostat.

3. Remove the gasket.

Refitting

1. Place the water pump (1a), complete with cover, bracket and gasket, back in its housing, then tighten the bolts (1b) to the recommended torque.

2. Fit the fixed timing belt tensioner (2a) and secure by tightening the bolt (2b) to the recommended torque.

1. Carry out a preliminary check on the camshaft timing: fit a spanner in the special opening (1a) in the centre of the camshafts and rotate them until the reference marks (1b) on the actual shafts coincide with the cylinder head upper surface.

The reference marks should be facing the centre of each cylinder head.

1. Remove the camshaft caps 4 and 7 from the left cylinder head.

2. Remove the camshaft caps B and G from the right cylinder head.

1. Position the timing templates in place of the camshaft caps removed.

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction, making sure that the drive sections are firmly taut.

1. Fit the tool (1a) and secure it with the bolt (1b) to the alternator bracket and with the bolt (1c) to the water pump.

The tool tooth should press on the moving part of the timing belt tensioner.

2. Act on the nut (2a) for the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) fixing the driven pullies to the recommended toruqe using the tool (1b) for counter-torque.

Remove the tools for timing the camshafts.

Place the camshaft caps back in their housings in place of the tools removed and tighten the bolts to the recommended torque.

Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.

1. Check that the moving reference on the timing belt moving tensioner lines up with the fixed reference.

2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned.

3. Tighten the bolts for the moving tensioner to the recommended torque.

Remove the belt tensioner tool.

1. Place the cylinder head tappet covers (1a) complete with gaskets back in their housings and secure them tightening the bolts (1b) to the recommended torque.

Place the bracket back in its housing and secure it using the bolts.

Place the lower protective timing covers back in their housings and secure them using the bolts.

Fit the upper protective timing gear cover and fix it using the bolts.

1. Place the ignition coils (1a) back in their housings on the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

Place the electrical wiring back in its housing and fasten it using the bolts.

Connect the electrical connections to the left cylinder head ignition coils.

Connect the electrical connections to the left cylinder head injectors.

Fit the ignition coils cover in the housing on the left cylinder head and fix it using the bolts.

Connect the earth lead to the left cylinder head and secure using the nut.

1. Place the ignition coils (1a) back in their housing on the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

Place the electrical wiring back in its housing and fasten it using the bolts.

Connect the electrical connections to the right cylinder head ignition coils.

Connect the electrical connections to the right cylinder head injectors.

Place the air chamber back in its housing and secure it using the bolts.

Tighten the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.

Connect the earth lead to the air chamber and secure it using the bolt.

Connect the electrical connection to the throttle body integrated with the D.V.L.

Tighten the band fastening the engine oil vapour recovery pipe to the air chamber.

Tighten the bands fixing the inlet ducts to the air chamber.

Connect the electrical connection for the detonation sensor, timing side.

Close the electrical connection box cover.

Proceed with refitting - 1004D40 engine - position on stand and remove.

1.9 JTD 8V

Removing

Proceed with the removal - 1032B16 toothed timing belt - r r with engine removed.

1. Undo the bolt (1a) of the driven pulley using the tools (1b) for counter-torque.

2. Remove the driven pulley.

1. Undo the bolts (1a) and remove the cam angle sensor (1b).

1. Undo the bolts (1a) and remove the water pump (1b) complete with O-Ring (1c).

Refitting

Refit the water pump, complete with a new O-ring, back in its housing and tighten the bolts to the specified torque.

Place the cam angle sensor back in its housing and fix it using the bolt.

Refit the toothed driven timing pulley into its housing.

Tighten the driven pulley bolt to the specified torque using the tools for counter-torque.

Proceed with the refitting - 1032B16 toothed timing belt - r r with engine removed.

1.9 JTD 16V

Removing

Proceed with removal - 1032B16 toothed timing belt - r r with engine removed.

1. Undo the bolts (1a) and remove the water pump (1b) complete with gasket (1c).

Refitting

Place the water pump complete with gasket, back in its housing and secure it by tightening the bolts to the recommended torque.

.Proceed with refitting - 1032B16 toothed timing belt - r r with engine removed.