REPLACING THE WATER PUMP

Replacing The Coolant Pump Draining the coolant *Remove: *the cap for the expansion tank *the splash guard under the engine. *Position a container under the engine drain cock. Drain the engine coolant. *Avoid skin contact with the coolant. *Transfer the container to the radiator drain cock. Drain off the remaining coolant. *Close the nipples. Install the splash guard under the engine. Removing the auxiliaries belt

*Slacken off the auxiliaries belt by turning the screw on the tension reel clockwise. *Remove the auxiliaries belt. Removing the timing covers Remove:

*the upper timing cover *the front timing cover. Installing the lifting beam and lifting hook *Install the lifting beam and the lifting hook. Removing the right-hand engine mounting *Remove the right engine mounting. Position the engine *Position the engine according to the marking. Removing the timing belt *Remove the timing belt. Removing the coolant pump

*Remove the screws tap the pump wheel using the shaft of a hammer. *Remove the pump *clean the gasket faces thoroughly. Installing the coolant pump Install:

*a new gasket *a new pump. Tighten the screws. Tighten to 17 Nm . Installing the timing belt Install the new belt in the following order:

*crankshaft *the idler pulley i*ntake camshaft *exhaust camshaft *water pump *belt tensioner. Tension the timing belt NOTE: This adjustment is to be made with a cold engine. Suitable temperature is approximately 20 degree C/67 degree F . At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The above figure shows the position of the indicator at different engine temperatures. *Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft

*Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window *Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm . Check that the indicator is in the correct position. Check Checking markings

*Press the belt to check that the indicator on the tensioner moves easily *Install the upper timing cover *Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond. NOTE: Check that the indicator on the belt tensioner is within the marked area. Installing timing covers Install:

*the lower timing cover *the front timing cover. Tighten to 12 Nm *the auxiliaries belt. Installing the right engine mounting *Screw the engine mounting into place on the engine. Tighten to 67 Nm . Install:

*the screws on the bracket for the bodywork. Tighten to 50 Nm *the servo reservoir. Finishing Remove the lifting beam and lifting hook. Install:

*the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt *the front wheel *the auxiliaries belt. Checking work Function test: *runs the engine to normal operating temperature until the thermostat opens *top up the cooling system if necessary. Check for leaks.