Water Pump: Service and Repair

REMOVAL
1. Loosen the expansion tank-cap and raise the car.
2. Remove the center air deflector, place a drip tray under the radiator and open the radiator drain plug. Lower the car.
3. Lift the power steering servo fluid reservoir and disconnect the cable from the torque arm engine mounting.
4. Remove the torque arm.
5. Remove the servo line clamp from the torque arm engine mounting and remove the engine mounting.
6. Slacken the coolant pump pulley. Relieve the load on the belt tensioner by turning the belt tensioner pulley retaining bolt forwards in the car using a 15 mm wrench. Remove the belt from the coolant pump pulley and carefully release the belt tensioner.
7. Detach the upper hose from the expansion tank and remove the coolant pump pulley.
8. Detach the upper part of the generator air intake and remove the belt tensioner.
9. Remove the servo pump.
10. Remove the timing cover.

NOTE: There is quite a lot of coolant left in the engine. Always have a drip tray under the engine when working on the cooling system.

11. Remove the coolant pump. Be careful with the O-ring.





INSTALLATION
1. Clean the sealing surfaces and install a new O-ring.
2. Coat the sealing surfaces and the O-ring with acid-free petroleum jelly and install the coolant pump
3. Install the timing cover.
4. Install the power steering servo pump.
5. Install the belt tensioner. Tightening torque 40 Nm (30 ft. lbs.).
6. Install the upper part of the generator air intake.
7. Install the coolant pump pulley and connect the upper hose to the expansion tank.
8. Relieve the load from the belt tensioner by turning the belt tensioner pulley forwards in the car using a 15 mm wrench. Install. the belt to the coolant pump pulley and check the position on the other pulleys. Carefully release the belt tensioner.
9. Install the torque arm engine mounting and install the servo line clip.
10. Install the torque arm. Screw the cable to the torque arm engine mounting and hook on the power steering servo fluid reservoir.
11. Raise the car, check that the radiator drain plug is tightened and install the center air deflector.
12. Lower the car, top up the coolant and check the system for leaks.
13. Bleed the system as follows:
a. Fill the system to the MAX level. Install the pressure cap. Start the engine and run it until warm, preferably at varying accelerator settings, until the radiator fan starts.
b. Remove the pressure cap and refill to MAX.
c. Install the pressure cap and let the engine run at varying accelerator settings until the radiator fan has started a further three times.
d. Switch off the engine and refill to the MAX level if necessary.