Water pump - r + r with engine removed

Operation 1088C20 · Water pump and thermostat

1.6 16v

Removing

Position the power unit on a suitable workbench.

1. Loosen the bolts (1a) for the moving tensioner and remove the alternator and water pump drive belt (1b) from the water pump pulley.

1.8 16v

Removing

- 1004D40 engine - position on stand and remove.

1. Fit the flywheel lock.

2.4 20v

Removing

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

1. Undo the bolts (1a) of the timing driven pulley, inlet side, using the tool (1b) for counter-torque.

2. Remove the timing driven pulley, inlet side.

1.9 JTD 8v

Removing

Proceed with 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 toothed driven pulley.

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).

1.6 16v

1. Undo the bolts (1a) and remove the power assisted steering pulley protection (1b).

2. Loosen the bolts fixing the power assisted steering pump.

3. Loosen the locknut (3a), then loosen the tension for the belt from the water pump to the power assisted steering pump via the tensioning screw (3b).

4. Remove the belt from the water pump to the power assisted steering pump.

1.8 16v

1. Undo the bolts (1a) and remove the single engine component belt drive pulley (1b).

2. Loosen the mobile timing belt tensioner nut.

3. Remove the timing belt.

Remove the flywheel lock.

2.4 20v

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

1.9 JTD 8v

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

1.9 JTD 16v

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

1.6 16v

Undo the nuts and remove the exhaust manifold heat shield.

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

2. Loosen the lower alternator fixing bolt.

3. Rotate the alternator downwards to gain access to the water pump fastenings.

1.8 16v

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 timing driven pulley, inlet side.

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

2.4 20v

Refitting

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

Place the inlet side timing driven pulley back in its housing.

Tighten the driven timing pulley bolts, inlet side, to the specified torque using the tool for counter-torque.

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

1.9 JTD 8v

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

1.6 16v

1. Undo the bolts fixing the water inlet rigid pipe to the water pump.

2. Undo the bolts (2a) and remove the water pump (2b) complete with support.

1.8 16v

Refitting

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

2. Fit the inlet side driven 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).

1.9 JTD 8v

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

1.6 16v

Refitting

1. Place the water pump (1a), complete with support, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

2. Tighten the bolts fixing the rigid coolant inlet pipe to the water pump to the recommended torque.

1.8 16v

1. Disconnect the electrical connections from the ignition coils.

2. Undo the bolts (2a) and remove the ignition coils (2b).

Disconnect the oil vapour recovery pipe from the rocker cover.

1.6 16v

Refit the alternator.

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

Tighten the lower alternator fixing bolt.

Place the exhaust manifold heat shield back in its housing and fix it using the nuts.

1. Place the belt from the water pump to the power assisted steering pump back in its housing.

2. Act on the adjustment screw (2a) until the tension for the belt between the water pump and the power assisted steering pump is within the recommended values which can be measured using the tool (2b).

3. Tighten the belt tensioner locknut.

4. Tighten the bolts fixing the power assisted steering pump.

5. Place the power assisted steering pump pulley protection (5a) back in its housing and secure it using the bolts (5b).

1.8 16v

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

1. Undo the bolt (1a) for the timing driven pulley, exhaust side using the tools (1b) and (1c) for counter-torque.

1.6 16v

1. Place the alternator and water pump drive belt back in its housing.

2. Use a spanner (2a), fitted in the hexagonal opening of the tensioning device (2b), then tighten the bolts (2c) for the moving tensioner.

3. Using the tool, check that the tension of the water pump drive belt is within the recommended values.

1.8 16v

Undo the bolts and remove the camshaft third cap.

Mark the position of the camshaft caps following removal so that they can be positioned correctly upon refitting.

1. Fit templates (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

1. Remove the engine oil pump retaining bolt.

2. Fit the timing belt.

3. Fit the pin of the tool for setting the engine to TDC.

4. Turn the crankshaft a little at a time to allow locating dowel (4a) on the pulley to fit into the hole on tool (4b).

5. Lock the tool in position using a nut (5a) and ordinary bolt (5b).

Complete the fitting of the toothed timing belt following the order:

• toothed drive pulley
• fixed tensioner,
• exhaust side toothed driven pulley,
• intake side toothed driven pulley
• moving tensioner,
• coolant pump pulley

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation. Three notches on the belt must also line up with notches on the toothed drive pulley and on the intake and exhaust toothed driven pulleys

1. Fit the tool into the hole on the timing belt mobile tensioner and turn to apply maximum tension to the timing belt.

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

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

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

Undo the bolts and remove the tool.

Remove the engine positioning and TDC tool.

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

Rotate the crankshaft through two revolutions in its normal direction of rotation.

Loosen the moving tensioner nut.

5. Fit tool (5a) in the hole on the mobile timing belt tensioner mount and turn to align the tensioner moving pointer (5b) with fixed reference (5c).

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

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

Connect the oil vapour recovery pipe to the rocker cover.

Place the ignition coils back in their housings and tighten them using the bolts.

Connect the electrical connections to the ignition coils.

Fit the flywheel lock.

Fit the single drive belt pulley and tighten the bolts to torque.

Tighten the bolt fixing the timing belt drive pulley to the recommended torque.

Remove the flywheel lock.

- 1004D40 engine - position on stand and remove.